CN117548649A - Casting method for temperature-pressure flow multi-field cooperative control, control device and application thereof - Google Patents
Casting method for temperature-pressure flow multi-field cooperative control, control device and application thereof Download PDFInfo
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- CN117548649A CN117548649A CN202410034591.8A CN202410034591A CN117548649A CN 117548649 A CN117548649 A CN 117548649A CN 202410034591 A CN202410034591 A CN 202410034591A CN 117548649 A CN117548649 A CN 117548649A
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- 238000005266 casting Methods 0.000 title claims abstract description 128
- 238000000034 method Methods 0.000 title claims abstract description 47
- 229910052751 metal Inorganic materials 0.000 claims abstract description 120
- 239000002184 metal Substances 0.000 claims abstract description 120
- 230000035772 mutation Effects 0.000 claims abstract description 25
- 230000008859 change Effects 0.000 claims description 22
- 238000009529 body temperature measurement Methods 0.000 claims description 18
- 238000007514 turning Methods 0.000 claims description 12
- 229910021652 non-ferrous alloy Inorganic materials 0.000 claims description 7
- 230000007246 mechanism Effects 0.000 claims description 6
- 229910018125 Al-Si Inorganic materials 0.000 claims description 3
- 229910018520 Al—Si Inorganic materials 0.000 claims description 3
- 238000004891 communication Methods 0.000 claims description 3
- 229910018137 Al-Zn Inorganic materials 0.000 claims description 2
- 229910018182 Al—Cu Inorganic materials 0.000 claims description 2
- 229910018573 Al—Zn Inorganic materials 0.000 claims description 2
- 238000007711 solidification Methods 0.000 abstract description 20
- 230000008023 solidification Effects 0.000 abstract description 20
- 230000001276 controlling effect Effects 0.000 abstract description 19
- 238000004519 manufacturing process Methods 0.000 abstract description 4
- 230000001105 regulatory effect Effects 0.000 abstract description 3
- 229910052782 aluminium Inorganic materials 0.000 description 22
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 22
- 230000000052 comparative effect Effects 0.000 description 16
- 230000007547 defect Effects 0.000 description 9
- 239000007788 liquid Substances 0.000 description 9
- 238000005516 engineering process Methods 0.000 description 8
- 230000008569 process Effects 0.000 description 7
- 238000010586 diagram Methods 0.000 description 5
- 238000009826 distribution Methods 0.000 description 5
- 230000007847 structural defect Effects 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- 238000005429 filling process Methods 0.000 description 4
- 238000012544 monitoring process Methods 0.000 description 4
- 238000007689 inspection Methods 0.000 description 3
- 230000003647 oxidation Effects 0.000 description 3
- 238000007254 oxidation reaction Methods 0.000 description 3
- 239000002893 slag Substances 0.000 description 3
- 238000012937 correction Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000005058 metal casting Methods 0.000 description 2
- 238000005457 optimization Methods 0.000 description 2
- 238000001878 scanning electron micrograph Methods 0.000 description 2
- 230000036962 time dependent Effects 0.000 description 2
- 238000013459 approach Methods 0.000 description 1
- 230000008094 contradictory effect Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 210000001787 dendrite Anatomy 0.000 description 1
- 238000013401 experimental design Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
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- 238000009864 tensile test Methods 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/08—Controlling, supervising, e.g. for safety reasons
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D2/00—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass
- B22D2/006—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass for the temperature of the molten metal
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Casting Support Devices, Ladles, And Melt Control Thereby (AREA)
Abstract
The invention provides a casting method for temperature-pressure flow multi-field cooperative control, a control device and application thereof, and the method comprises the following steps: setting a first temperature measuring point, a middle temperature measuring point and a last temperature measuring point on a die; pouring molten metal in the cavity, and applying casting pressure; under the condition that the molten metal reaches the first temperature measuring point, the casting pressure is pressurized on the basis of the initial pressure, and the filling speed of the molten metal is controlled to be 0.84 cm/s-2.1 cm/s; under the condition that the middle temperature measuring point detects that the molten metal reaches the corresponding structure mutation point, regulating casting pressure and regulating mold filling speed; until the last temperature measuring point detects that the molten metal reaches the tail end of the cavity, the mold filling is completed; and (5) pressurizing, maintaining pressure and releasing pressure sequentially on the die cavity to obtain the casting. The invention provides an intelligent closed-loop control method for cooperatively controlling a filling flow field, a solidification temperature field and a pressurizing pressure field in the pressurizing casting process, which stably and flexibly completes the whole-flow production of castings.
Description
Technical Field
The invention belongs to the field of casting, and particularly relates to a casting method for temperature-pressure flow multi-field cooperative control, a control device and application thereof.
Background
The pressure is used as an important parameter in the low-pressure or differential pressure casting process, and is mainly used for driving molten metal to finish filling the cavity and providing feeding power for solidification of the molten metal after filling.
The pressure control in the common technology is carried out in a time preset mode, and the five stages of liquid lifting, filling, pressurizing, pressure maintaining and pressure releasing in the low-pressure or differential-pressure casting process are all carried out by respectively setting the pressure of the corresponding time period. The problem that the filling process of the molten metal in the cavity cannot be accurately controlled and the feeding power required by the solidification of the molten metal cannot be timely provided often exists, so that a large amount of secondary oxidation slag inclusion is generated when the molten metal is filled in the cavity, and structural defects such as tiny shrinkage porosity and the like are generated after the solidification of the molten metal.
Based on this, it is necessary to provide a casting method with temperature, pressure and flow multi-field cooperative control, and a control device and application thereof, so as to alleviate or solve the above problems.
Disclosure of Invention
The invention aims to solve the technical problems that a large amount of secondary oxidation slag inclusion is generated when a mold cavity is filled with metal in the common technology, and structural defects such as tiny shrinkage porosity are generated after solidification, and provides a casting method with temperature-pressure flow multi-field cooperative control, which comprises the following steps:
setting a first temperature measuring point, a middle temperature measuring point and a last temperature measuring point on a die; the first temperature measuring point corresponds to a pouring position of the die, the middle temperature measuring point corresponds to at least part of structural mutation points in the die cavity, and the last temperature measuring point corresponds to the tail end of the die cavity;
pouring molten metal in the cavity, and applying casting pressure;
under the condition that the molten metal reaches the first temperature measuring point, the casting pressure is pressurized at a pressurizing rate of 2-5 mbar/s on the basis of the initial pressure, and the charging speed of the molten metal is controlled to be 0.84-2.1 cm/s;
under the condition that the intermediate temperature measuring point detects that the molten metal reaches a corresponding structure mutation point, increasing casting pressure and adjusting the mold filling speed; and along with the continuous increase of the distance between the middle temperature measuring point and the pouring position, the pressurizing rate of the casting pressure is gradually increased, and the filling speed is gradually increased;
the mold filling is completed until the last temperature measuring point detects that the molten metal reaches the tail end of the mold cavity, wherein the casting pressure when the molten metal reaches the tail end of the mold cavity is a first pressure, and the first pressure is 300 mbar/s-400 mbar/s;
and controlling the casting pressure to sequentially pressurize, maintain and release the pressure of the cavity on the basis of the first pressure to obtain the casting.
Further, the middle temperature measuring points comprise a second temperature measuring point, a third temperature measuring point and a fourth temperature measuring point which correspond to the structural mutation points which sequentially appear along the cavity;
under the condition that the intermediate temperature measuring point detects that the molten metal reaches the corresponding structure mutation point, increasing the casting pressure and adjusting the mold filling speed comprises the following steps:
under the condition that the second temperature measuring point detects the corresponding first pole, the casting pressure is boosted at a boosting rate of 2-15 mbar/s, and the filling speed of the molten metal is controlled to be 0.84-6.3 cm/s;
under the condition that the third temperature measuring point detects the corresponding first pole, the casting pressure is boosted at a boosting rate of 2-15 mbar/s, and the filling speed of the molten metal is controlled to be 0.84-6.3 cm/s;
under the condition that the fourth temperature measuring point detects the corresponding first pole, the casting pressure is boosted at a boosting rate of 2-15 mbar/s, and the filling speed of the molten metal is controlled to be 0.84-6.3 cm/s;
the first pole is the moment when the molten metal starts to shield the structure mutation point corresponding to the corresponding temperature measurement point.
Further, the last temperature measuring point includes the fifth temperature measuring point, controlling the casting pressure to sequentially pressurize, maintain and release the cavity based on the first pressure further includes:
under the condition that the fifth temperature measuring point detects the corresponding first pole, the casting pressure is pressurized to a second pressure for maintaining pressure under the condition that the pressurizing rate is 60 mbar/s-100 mbar/s, wherein the second pressure is 850 mbar-1500 mbar;
under the condition that the fourth temperature measuring point detects the corresponding second pole, adjusting the pressurizing rate to 50 mbar/s-80 mbar/s, pressurizing to third pressure, and maintaining the pressure, wherein the third pressure is 2500 mbar-3500 mbar;
under the condition that the second temperature measuring point detects a corresponding second pole, adjusting the pressurizing frequency to 40 mbar/s-60 mbar/s, pressurizing to fourth pressure, and maintaining the pressure, wherein the fourth pressure is 2500 mbar-3500 mbar;
releasing pressure to 0 under the condition that the first temperature measuring point detects a corresponding second pole;
the second pole is the moment when the corresponding molten metal starts to solidify at the corresponding temperature measuring point.
Further, the initial pressure is 160-240 mbar.
Further, before the molten metal is detected to reach the first temperature measuring point, the casting pressure is boosted from 0mbar to the initial pressure at a boosting rate of 16mbar/s to 24mbar/s, so that the liquid lifting of the molten metal is realized.
Further, the molten metal includes an Al-Si-based cast nonferrous alloy, an Al-Cu-based cast nonferrous alloy, and an Al-Zn-based cast nonferrous alloy.
Further, the step of releasing the pressure to 0 in the case that the first temperature measuring point detects the corresponding second pole includes reducing the casting pressure to 0 at a pressure-reducing rate of 200mbar/s to 400 mbar/s.
The invention provides the use of a casting method as defined in any one of the above in the casting of wheels.
Further, the cavity is a wheel casting cavity, the wheel casting cavity comprises a rim position and a spoke position, and the first temperature measuring point corresponds to the pouring position at the spoke position and is arranged at the flange connection position of the spoke; the middle temperature measuring point comprises a second temperature measuring point, a third temperature measuring point and a fourth temperature measuring point;
the second temperature measuring point corresponds to a wall turning part of the spoke position;
the third temperature measuring point corresponds to the connecting turning thick wall of the spoke position and the rim position;
the fourth temperature measuring point corresponds to the connecting turning thin wall of the spoke position and the rim position;
and the last temperature measuring point corresponds to one end of the rim position far away from the pouring position.
The invention also provides a control device for the temperature-pressure flow multi-field cooperative control, which is applied to the casting method for the temperature-pressure flow multi-field cooperative control according to any one of the above or the application of the casting method in wheel casting, wherein the control device comprises the following components:
the N temperature measuring devices are arranged corresponding to the first temperature measuring point, the middle temperature measuring point and the last temperature measuring point and are used for detecting the temperature of each temperature measuring point;
the first calculating mechanism is used for calculating the change rate of the temperature of each temperature measuring point along with time and determining that the corresponding temperature measuring point reaches the first pole under the condition that the change rate of the measured temperature of the nth temperature measuring device along with time is 0 for the first time; and determining that the corresponding temperature measuring point reaches the second pole under the condition that the change rate of the measured temperature of the nth temperature measuring device along with time is 0 again; wherein N is the serial number of N temperature measuring devices, N is more than 0 and less than or equal to N;
and the pressurizing parameter processor is in communication connection with the N temperature measuring devices and the first computing mechanism, and adjusts the pressurizing parameters according to the condition that each temperature measuring point reaches a standing point, wherein the pressurizing parameters comprise pressure, pressurizing rate and depressurizing rate.
Compared with the prior art, the invention at least comprises the following advantages:
the invention provides a casting method with cooperative control of temperature, pressure and flow fields, which realizes the operation monitoring of a cavity flow field and a temperature field by utilizing the arrangement of temperature measuring points at the head and the tail of the cavity and the abrupt structural position. Based on the temperature change rule of each temperature measuring point along with the operation of the flow field, the method can obtain: when the metal liquid shields the structure mutation point corresponding to the temperature measuring point, the temperature measuring point reaches the first pole; when the molten metal corresponding to the temperature measuring point starts to solidify, the temperature measuring point reaches a second point; wherein, the last temperature measuring point reaches the first pole, which means that the filling is completed, and the molten metal at the last temperature measuring point starts to solidify.
The pole can intuitively prompt the casting process, and can realize the three-field cooperative control of the filling flow field, the solidification temperature field and the pressurizing pressure field by combining with the pressure parameter adjustment, and the whole casting pressurizing process is flexible and stable, timely in deviation correction, and can adaptively adjust the pressure parameter according to the structural characteristics of the casting so as to approximate to the expected control effect.
Therefore, the invention also gives consideration to the optimization of the quality of the casting product, and avoids turbulence caused by unsuitable pressure setting in the common technology: the molten metal is uniformly distributed in the cavity, so that the molten metal casting die has the advantages of no turbulence, low resistance, excellent mechanical properties such as strength and toughness, high dimensional accuracy, smooth and flat casting surface, and no defects such as cracks and air holes.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to the structures shown in these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a schematic diagram of a regular curve of temperature change of each temperature measuring point (including a first temperature measuring point, a second temperature measuring point, a third temperature measuring point, a fourth temperature measuring point and a fifth temperature measuring point) with time according to an embodiment of the present invention.
Fig. 2 is a schematic diagram showing the position distribution of each temperature measuring point in the single-sided wheel casting cavity in embodiment 1 of the present invention, wherein: 1 is a first temperature measuring point, 2 is a second temperature measuring point, 3 is a third temperature measuring point, 4 is a fourth temperature measuring point, 5 is a fifth temperature measuring point, 6 is a cavity indicated by the cavity, 7 is a top mold, 8 is a side mold, and 9 is a bottom mold.
FIG. 3 is a graph showing the differential pressure values as a function of temperature during the filling stage in example 1 of the present invention.
FIG. 4 is a graph showing the differential value of the total process pressure of the liquid-lifting-filling-pressurizing-depressurizing-pressure-releasing according to the temperature function in example 1 of the present invention.
FIG. 5 is an X-ray inspection chart of an aluminum wheel manufactured in example 1 of the present invention.
FIG. 6 is a physical view of the rim portion of the aluminum wheel manufactured in example 1 of the present invention.
FIG. 7 is a metallographic view of an aluminum wheel produced in example 1 of the present invention.
Fig. 8 is a graph showing the mechanical properties of the rim portion of the aluminum wheel manufactured in example 1 of the present invention.
FIG. 9 is a scanning electron micrograph of a tensile fracture at the rim portion of an aluminum wheel manufactured in example 1 of the present invention.
FIG. 10 is a graph showing the pressure of the conventional pressurizing process according to comparative example 1 of the present invention with time.
FIG. 11 is an X-ray examination of an aluminum wheel produced by the conventional pressurizing method in comparative example 1 of the present invention.
FIG. 12 is a physical view of the rim portion of the aluminum wheel product produced by the conventional pressurizing method of comparative example 1 of the present invention.
FIG. 13 is a metallographic structure diagram of an aluminum wheel product produced by the conventional pressurizing method in comparative example 1 of the present invention.
FIG. 14 is a graph showing the mechanical properties of the rim portion of an aluminum wheel produced by the conventional pressurizing method in comparative example 1 of the present invention.
FIG. 15 is a scanning electron micrograph of a tensile fracture at the rim of an aluminum wheel produced by the conventional pressurization method in comparative example 1 of the present invention.
FIG. 16 is a photograph of a fracture scanning electron microscope of a tensile specimen of the spoke portion after parameter adjustment in comparative example 2 of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made in detail and with reference to the accompanying drawings, wherein it is apparent that the embodiments described are only some, but not all embodiments of the present invention. All other embodiments, based on the embodiments of the invention, which are apparent to those of ordinary skill in the art without inventive faculty, are intended to be within the scope of the invention.
Moreover, the technical solutions of the embodiments of the present invention may be combined with each other, but it is necessary to be based on the fact that those skilled in the art can implement the embodiments, and when the technical solutions are contradictory or cannot be implemented, it should be considered that the combination of the technical solutions does not exist, and is not within the scope of protection claimed by the present invention.
Where numerical ranges are provided in the examples, it is understood that unless otherwise stated herein, both endpoints of each numerical range and any number between the two endpoints are significant both in the numerical range. 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 invention belongs and to which this invention belongs, and any method, apparatus, or material of the prior art similar or identical to the methods, apparatus, or materials of the embodiments of the invention may be used to practice the invention.
In the conventional technology, as shown in fig. 10, the casting technology involving pressure control, such as low pressure or differential pressure, generally includes five stages of "liquid lifting-filling-pressurizing-pressure maintaining-pressure releasing", wherein the stages are all to preset the pressure of the molten metal in different time periods so as to obtain a casting with compact structure and good mechanical properties.
However, the above-mentioned conventional techniques generally have the following problems: firstly, the pressure control mode of molten metal in the common technology cannot accurately control the filling process of the molten metal in a cavity: the filling effect is closely related to the structure of the cavity and the flow velocity of the molten metal, when the structure mutation points in the cavity are faced, the flow resistance is increased, the flow environment becomes complex, the flow velocity of the molten metal is not stable, and the molten metal is easy to generate turbulence under the impact of turbulence. The single staged pressure setting makes the molten metal unable to adaptively adjust the flow velocity according to the structure of the cavity, and the turbulence phenomenon cannot be avoided.
Secondly, because practice is different from experimental design, the feeding pressure is very easy to generate in and out with the required feeding power according to the feeding time when the time preset pressure is difficult to hit in a practice scene, if feeding is not in time or power is insufficient, shrinkage defects are generated in the casting, and the defects can influence the quality and performance of the casting, such as strength, wear resistance, corrosion resistance and the like.
In order to solve the technical problems faced in the prior art, the invention provides a casting method for controlling temperature, pressure and flow in a multi-field mode, which comprises the following steps:
s1, setting a first temperature measuring point, a middle temperature measuring point and a last temperature measuring point on a die; the first temperature measuring point corresponds to a pouring position of a cavity of the die, the middle temperature measuring point corresponds to at least part of structural abrupt points in the cavity, and the last temperature measuring point corresponds to the tail end of the cavity.
The first temperature measuring point corresponds to a casting position of a cavity of the mold, wherein the corresponding meaning is that the casting position is located in a measuring range of the first temperature measuring point. The first temperature measuring point is in direct contact with the casting site, i.e. in the cavity surface, for example. Also illustratively, the first temperature measurement point is not in direct contact with the casting site and is located outside of the cavity surface. If the first temperature measuring point is located on the cross section of the cavity surface where the pouring position is located in the die, a distance is formed between the first temperature measuring point and the cavity surface, and in some specific embodiments, the distance is 3-7 mm from the cavity surface.
The corresponding relation between the middle temperature measuring point and the structure mutation point, and the corresponding relation between the last temperature measuring point and the tail end of the cavity are similar, and will not be repeated.
The corresponding points are points, wherein the middle temperature measuring point is positioned at the cross section of the cavity surface where at least part of the structure abrupt change points are positioned in the mold and is 3-7 mm away from the cavity surface, the first temperature measuring point is positioned at the cross section of the cavity surface where the pouring position is positioned in the mold and is 3-7 mm away from the cavity surface, and inflow or solidification of molten metal is monitored in real time through temperature change; and the last temperature measuring point is positioned at the cross section of the end, far away from the pouring position, of the cavity in the die and is 3-7 mm away from the cavity surface so as to monitor whether the filling is finished. The temperature measuring point can accurately measure the temperature of the molten metal at the position corresponding to the temperature measuring point in real time.
For easy understanding, as shown in fig. 2, 7 is a top mold, 8 is a side mold, 9 is a bottom mold, and the cavity formed by the three molds is a cavity.
That is, the mold may include a top mold, a side mold, and a bottom mold.
It should be noted that the end of the cavity corresponding to the last temperature measurement point is shielded by the molten metal, which means that the filling is completed, that is, the molten metal at the last temperature measurement point starts to solidify.
The number of the middle temperature measuring points can be set according to the number of all the structural mutation points in the cavity, and the number of the structural mutation points is as large as possible. When the number of the middle temperature measuring points cannot cover the number of all the structural mutation points in the cavity, the distribution of the middle temperature measuring points can be as uniform as possible, and the situation that the distribution is too disordered is avoided. For example: the temperature measuring points corresponding to the structural mutation points of the first half section in the cavity are distributed in a concentrated mode, and the temperature measuring points corresponding to the structural mutation points of the second half section are scattered and sparse.
In some embodiments, the above-described "monitoring inflow or solidification of molten metal in real time" is performed in the following manner: referring to fig. 1, fig. 1 is a time-dependent temperature change chart of each temperature measurement point, and based on the temperature change rule, it can be obtained that: when the temperature measuring point reaches the first pole, the change rate of the molten metal temperature corresponding to the temperature measuring point along with time is 0 for the first time, and the molten metal shields the structural mutation point corresponding to the temperature measuring point; when the temperature measuring point reaches the second point, the change rate of the molten metal temperature corresponding to the temperature measuring point along with time is 0 again, and the molten metal corresponding to the temperature measuring point starts to solidify.
The first pole is the moment when the molten metal starts to shield the structural mutation point corresponding to the corresponding temperature measuring point, and the second pole is the moment when the molten metal corresponding to the corresponding temperature measuring point starts to solidify.
The last temperature measuring point is positioned at the tail end of the cavity, and when the last temperature measuring point reaches the first pole, the filling is completed, and then the molten metal at the last temperature measuring point starts to solidify.
In some embodiments, the cavity comprises a wheel casting cavity 6. In this embodiment, the intermediate temperature measuring points may include a second temperature measuring point 2, a third temperature measuring point 3, and a fourth temperature measuring point 4, which correspond to the structural discontinuities that occur sequentially along the wheel casting cavity 6, respectively. As shown in fig. 2, the wheel casting cavity 6 comprises a rim position and a spoke position, and the first temperature measuring point 1 corresponds to a pouring position at the spoke position, namely a flange connection position;
the second temperature measuring point 2 corresponds to a wall turning part of the spoke position;
the third temperature measuring point 3 corresponds to the connecting turning thick wall of the spoke position and the rim position;
the fourth temperature measuring point 4 corresponds to the connecting turning thin wall of the spoke position and the rim position;
and the fifth temperature measuring point 5 corresponds to the tail end of the cavity, namely one end of the rim position far away from the pouring position.
The corresponding points are that the second temperature measuring point 2 is positioned at the cross section of the cavity surface where the wall surface turning part of the spoke position is positioned in the mold and is 3-7 mm away from the outer wall of the cavity, the third temperature measuring point 3 is positioned at the cross section of the cavity surface where the spoke position and the rim position are connected with the turning thick wall position in the mold and is 3-7 mm away from the cavity surface, and the fourth temperature measuring point 4 is positioned at the cross section of the cavity surface where the spoke position and the rim position are connected with the turning thin wall position in the mold and is 3-7 mm away from the cavity surface;
the first temperature measuring point 1 is positioned at a position 3-7 mm away from the cross section of the cavity surface where the pouring position is positioned in the die, so as to monitor the inflow or solidification of the molten metal in real time; and the last temperature measuring point (namely a fifth temperature measuring point 5) is positioned at the cross section of the end of the middle cavity of the mold far away from the pouring position and is 3-7 mm away from the cavity surface so as to monitor whether the mold filling is completed or not. The temperature measuring point can accurately measure the temperature of the molten metal at the position corresponding to the temperature measuring point in real time.
S2, casting molten metal in the cavity, and applying casting pressure.
The molten metal is injected into the cavity by the liquid lifting pipe, the pressurizing device is connected below the liquid lifting pipe, and casting pressure is applied to the liquid lifting pipe through the pressurizing device so as to overcome the flow resistance of the molten metal in the flowing and filling process, so that the filling efficiency is improved.
In some embodiments, the molten metal comprises an Al-Si based, al-Cu based, al-Zn based cast nonferrous alloy. The viscosity of the molten metal can be 0.5-3 Pa.s.
S3, under the condition that the molten metal reaches the first temperature measuring point, the casting pressure is pressurized at a pressurizing rate of 2-5 mbar/s on the basis of the initial pressure, and the filling speed of the molten metal is controlled to be 0.84-2.1 cm/s.
In some embodiments, the manner of detecting the arrival of the molten metal at the first temperature measuring point may be as follows: as shown in fig. 1, when the molten metal reaches the first temperature measuring point, the rate of change of the temperature of the first temperature measuring point with time is 0.
And because the position of the first temperature measuring point corresponds to the casting phase, the molten metal reaches the first temperature measuring point: molten metal enters the cavity.
In some embodiments, the casting pressure is boosted from 0mbar to an initial pressure at a boost rate of 16mbar/s to 24mbar/s before the molten metal is detected to reach the first temperature measurement point to effect a boost of molten metal.
The initial pressure is, for example, 160mbar/s to 240mbar/s.
S4, under the condition that the middle temperature measuring point detects that the molten metal reaches the corresponding structure mutation point, increasing casting pressure and adjusting the mold filling speed; and along with the continuous increase of the distance between the middle temperature measuring point and the pouring position, the pressurizing rate of the casting pressure is gradually increased, and the filling speed is gradually increased.
In some embodiments, the intermediate temperature points include a second temperature point, a third temperature point, and a fourth temperature point that correspond to respective structural discontinuities that occur sequentially along the cavity. When the intermediate temperature measurement point is set as above, the pressure setting scheme can be adapted to most cavity structures.
In some embodiments, as shown in fig. 3, in the case that the intermediate temperature measuring point detects that the molten metal reaches the corresponding structural abrupt change point, increasing the casting pressure and adjusting the mold-filling speed further includes:
s41, under the condition that the fact that the molten metal reaches the first pole is detected through the second temperature measuring point, the casting pressure is boosted at a boosting rate of 2-15 mbar/s, and the filling speed of the molten metal is controlled to be 0.84-6.3 cm/s.
Illustratively, when the cavity is a wheel casting cavity, step S41 controls the rate of filling the spoke portion of the casting cavity with molten metal.
S42, under the condition that the third temperature measuring point detects the first pole, the casting pressure is boosted at a boosting rate of 2 mbar/s-15 mbar/s, and the filling speed of molten metal is controlled to be 0.84 cm/s-6.3 cm/s;
when the cavity is a wheel casting cavity, the step S42 controls the filling speed of the molten metal to the joint portion of the spoke and the rim in the casting cavity.
S43, under the condition that the fourth temperature measuring point detects the first pole, the casting pressure is boosted at a boosting rate of 2 mbar/s-15 mbar/s, and the filling speed of molten metal is controlled to be 0.84 cm/s-6.3 cm/s;
under the condition that each temperature measuring point reaches the first pole, the molten metal starts to shield the structure mutation point corresponding to each temperature measuring point, and each temperature measuring point comprises a first temperature measuring point, a second temperature measuring point, a third temperature measuring point, a fourth temperature measuring point and a fifth temperature measuring point.
For example, when the cavity is a wheel casting cavity, step S43 controls the filling speed of the molten metal to the joint portion of the spoke and the rim in the casting cavity.
S5, completing filling until the last temperature measuring point detects that the molten metal reaches the tail end of the cavity, wherein the pressure when the molten metal reaches the tail end of the cavity is a first pressure which is 160-240 mbar;
s6, controlling the casting pressure to sequentially pressurize, maintain and relieve pressure of the cavity to obtain the casting.
In some embodiments, the last temperature measurement point includes a fifth temperature measurement point.
In some embodiments, as shown in fig. 4, controlling the casting pressure to sequentially pressurize, and depressurize the cavity further comprises:
s61, under the condition that the fifth temperature measuring point detects the first pole, the filling is completed, the pressurizing rate is adjusted to 60 mbar/s-100 mbar/s, the pressure is increased to the second pressure, and the second pressure is 850 mbar-1500 mbar.
In some embodiments, the filling is completed after the fifth temperature measuring point reaches the first pole, and solidification of the molten metal at the corresponding fifth temperature measuring point is started.
And when the fifth temperature measuring point reaches the first pole, feeding power is provided timely, so that the structural integrity of the casting can be ensured, and the occurrence of structural defects is reduced.
Illustratively, when the cavity is a wheel casting cavity, step S61 provides sufficient feeding power for solidification of the rim portion.
S62, under the condition that the fourth temperature measuring point detects the second pole, the pressurizing rate is adjusted to 50 mbar/s-80 mbar/s, the pressure is increased to third pressure, and the third pressure is 2500 mbar-3500 mbar.
Illustratively, when the cavity is a wheel casting cavity, step S61 provides sufficient feeding power for the spoke portion to solidify.
S63, under the condition that the second temperature measuring point detects the second pole, the pressurizing frequency is adjusted to 40 mbar/s-60 mbar/s, the pressure is increased to fourth pressure, and the fourth pressure is 2500 mbar-3500 mbar.
Illustratively, when the cavity is a wheel casting cavity, step S61 provides sufficient feeding power for the flange portion to solidify.
S64, under the condition that the first temperature measuring point detects the second pole, the pressure is relieved to 0. And after solidification of the molten metal is completed, the pressure in the heat preservation furnace is timely released, the mold sticking site is prevented from being caused by overlong pouring gate, and the production efficiency is improved.
When each temperature measuring point reaches the second pole, the molten metal corresponding to each temperature measuring point starts to solidify.
Compared with the prior art, the invention at least comprises the following advantages:
the invention provides an intelligent closed-loop control method for cooperatively controlling a filling flow field, a solidification temperature field and a pressurizing pressure field in the pressurizing casting process. The operation monitoring of the cavity flow field and the temperature field is realized by utilizing the arrangement of the temperature measuring points at the first and the last of the cavity and the abrupt structural change, as shown in fig. 1, the temperature change of each temperature measuring point along with the operation of the flow field in the invention can be obtained based on the temperature change rule: when the temperature measuring point reaches the first pole, the molten metal shields the structure mutation point corresponding to the temperature measuring point; when the temperature measuring point reaches the second point, the molten metal corresponding to the temperature measuring point starts to solidify.
The three fields of the filling flow field, the solidification temperature field and the pressurizing pressure field are cooperatively controlled by combining with the pressure parameter adjustment, the pressurizing process of the casting in the whole process is flexible and stable, the correction is timely, the pressure parameter can be adaptively adjusted according to the structural characteristics of the casting so as to approach the expected control effect, and the problems that the conventional technology based on time control pressurizing has no feedback, cannot be accurately controlled and cannot be controlled in a closed loop are solved;
the quality optimization of the casting products is also considered, so that the problems of turbulence caused by unsuitable pressure setting in the common technology, oxide inclusion caused by untimely feeding power supply, structural defects and other casting products are avoided: the molten metal is uniformly distributed in the cavity, so that the molten metal casting die has the advantages of no turbulence, low resistance, excellent mechanical properties such as strength and toughness, high dimensional accuracy, smooth and flat casting surface, and no defects such as cracks and air holes.
Specifically, the molten metal flows into the cavity from the self to the solidification, and is in the three-field cooperative monitoring of the filling flow field, the solidification temperature field and the pressurization pressure field. When the die cavity structure where the molten metal is located is suddenly changed, the temperature measuring point state is updated, the casting pressure applying system responds rapidly, the flow speed of the molten metal changes to adapt to the die cavity structure suddenly changed at the position, the molten metal can stably pass through, and the die filling process of the molten metal in the die cavity is accurately controlled.
In addition, based on the setting of the last temperature measuring point, when the filling is finished, the state of the last temperature measuring point is quickly updated to reach the first pole, and the pressurizing rate is quickly increased in a transition mode to provide enough feeding power for the molten metal to be solidified. With the sequential updating of the states of the temperature measuring points of the following N-1, N-2, N-3 and the following I.A. 1, the casting pressure is continuously adjusted, the casting quality is further optimized, and the structural defects are avoided.
The invention also provides an application of the casting method in wheel casting.
The invention also provides a control device for the temperature-pressure flow multi-field cooperative control, which is applied to the casting method for the temperature-pressure flow multi-field cooperative control according to any one of the above, and comprises the following steps:
the N temperature measuring devices are sequentially arranged from the pouring position according to the distribution of structural mutation points of the cavity and are used for detecting the temperature of each temperature measuring point;
the first calculating mechanism is used for calculating the change rate of the temperature of each temperature measuring point along with time, and when the change rate of the temperature of the nth temperature measuring point along with time is 0 for the first time, the nth temperature measuring point reaches the first pole; under the condition that the change rate of the nth temperature measuring point along with time is 0 again, the nth temperature measuring point reaches the second pole; wherein N is more than 0 and less than or equal to N;
and the pressurizing parameter processor is in communication connection with the N temperature measuring devices and the first computing mechanism, and adjusts pressurizing parameters according to the temperature of each temperature measuring point and whether the structural mutation point corresponding to each temperature measuring point is shielded by the molten metal, wherein the pressurizing parameters comprise pressure, pressurizing rate and depressurizing rate.
To facilitate a further understanding of the invention by those skilled in the art, reference is now made to the accompanying drawings, in which:
example 1
As shown in FIG. 2, under the condition that the first temperature measuring point reaches the first pole, the filling speed of the molten metal just entering the casting mold cavity after the completion of liquid lifting is controlled, the pressurizing speed is controlled to be 3.5mbar/s, and the filling speed of the molten metal is controlled to be 1.5cm/s.
Under the condition that the second temperature measuring point reaches the first pole, controlling the filling speed of the molten metal to the spoke part in the casting mold cavity, controlling the pressurizing speed to be 6mbar/s, and controlling the filling speed of the molten metal to be 2.5cm/s.
Under the condition that the third temperature measuring point reaches the first pole, controlling the filling speed of the molten metal to the joint part of the spoke and the rim in the casting mold cavity, controlling the pressurizing speed to 8mbar/s, and controlling the filling speed of the molten metal to 3.3cm/s.
Under the condition that the fourth temperature measuring point reaches the first pole, controlling the filling speed of the molten metal to the rim part in the casting mold cavity, controlling the pressurizing speed to be 12.5mbar/s, and controlling the filling speed of the molten metal to be 5.2cm/s.
Under the condition that the fifth temperature measuring point reaches the first pole, the first pressure is 320mbar, the primary pressurization is started, the pressurization rate is not less than 60mbar/s, the final pressure (namely the second pressure) of the primary pressurization is controlled between 1200mbar, and sufficient feeding power is provided for solidification of the rim part.
Under the condition that the fourth temperature measuring point reaches the second pole, the second-stage pressurization is started, the pressurization rate is not less than 50mbar/s, the final pressure (namely the third pressure) of the second-stage pressurization is controlled at 2300mbar, and sufficient feeding power is provided for solidification of the spoke part.
Under the condition that the second temperature measuring point reaches the second pole, three-stage pressurization is started, the pressurization rate is not less than 40mbar/s, the final pressure (namely fourth pressure) of the three-stage pressurization is controlled at 3000mbar, and sufficient feeding power is provided for solidification of the flange part.
According to the second pole of the first temperature measuring point, pressure relief is started, the pressure in the holding furnace is released in time after the solidification of the molten metal is completed, the mold sticking site is prevented from being caused by overlong pouring gate, and the production efficiency is improved.
Fig. 5 is an X-ray inspection chart of an aluminum wheel produced by the method.
Fig. 6 is a physical view of the rim portion of the aluminum wheel product manufactured by the embodiment, and the surface of the rim portion is flat and smooth.
Fig. 7 is a metallographic structure diagram of the aluminum wheel product prepared by the embodiment, and fig. 5 shows that the product has uniform component distribution, no obvious segregation phenomenon, stable structure and no obvious defect.
Fig. 8 is a graph showing the mechanical properties of the rim portion of the aluminum wheel manufactured in this example, and the experimental results are shown in the following table:
table 1: mechanical property meter for rim part of aluminum wheel prepared in example 1
Fig. 9 is a scanning electron microscope photograph of a tensile fracture at the rim portion of an aluminum wheel manufactured in this example.
Comparative example 1
Using the conventional pressurization process shown in fig. 10, specific pressurization parameters are shown in table 1, pressurization is started at a rate of 20mbar/s, and molten metal is default to enter the cavity at the 10 th s; the mold filling was then started at a rate of 8mbar/s and the mold cavity was filled with molten metal by default at 30s, then continued to be pressurized at 61.25mbar/s until 850mbar starts to solidify, at 238s pressure relief was started at 21.25mbar/s, and finally the mold was opened at 278s to complete the production.
Table 2: pressure time-dependent table of conventional pressurization process in comparative example 1
Fig. 11 is an X-ray inspection chart of an aluminum wheel produced by the conventional pressurizing method in this comparative example, which shows that shrinkage defects are significantly scattered in the red coil region.
Fig. 12 is a physical view of the rim portion of the aluminum wheel product produced by the conventional pressing method in this comparative example, and it can be seen that the rim has macroscopic fine shrinkage defects (black dot shape) after machining.
FIG. 13 is a metallographic structure diagram of an aluminum wheel product produced by the conventional pressurizing method in the comparative example, wherein the black part is shrinkage porosity defect.
Fig. 14 is a graph of mechanical properties of rim portions of an aluminum wheel produced by the conventional pressurization method in this comparative example, and the lateral extension of the graph is significantly shorter than that of fig. 8, indicating rapid generation and propagation of cracks to fracture after deformation. The experimental results are shown in the following table.
Table 3: mechanical property meter for rim part of aluminum wheel prepared in comparative example 1
Fig. 15 is a scanning electron microscope photograph of a tensile fracture at the rim of an aluminum wheel produced by a conventional pressurization method. It can be seen that the fracture showed 3 distinct shrinkage porosity defects and that there were a large number of surface-rounded α -Al dendrites on the fracture surface, indicating severe underfeeding here, with a significant difference from the large number of small dimples shown in the fracture of fig. 9.
Comparative example 2
And only the pressurizing speed of the first two sections of the method is regulated, under the condition that the first temperature measuring point reaches the first pole, the pressurizing speed of the molten metal just entering the casting mold cavity after the liquid rising is controlled to be 6mbar/s, and the pressurizing speed of the molten metal is controlled to be 2.5cm/s.
Under the condition that the second temperature measuring point reaches the first pole, controlling the mold filling speed of the molten metal to the spoke part in the casting mold cavity, controlling the pressurizing speed to be 10mbar/s, and controlling the mold filling speed of the molten metal to be 4.2cm/s.
FIG. 16 shows the fracture of the tensile test specimen at the spoke portion after the parameter adjustment in comparative example 2, which shows that the secondary oxidation slag inclusion is serious.
In the above technical solution of the present invention, the above is only a preferred embodiment of the present invention, and therefore, the patent scope of the present invention is not limited thereto, and all the equivalent structural changes made by the description of the present invention and the content of the accompanying drawings or the direct/indirect application in other related technical fields are included in the patent protection scope of the present invention.
Claims (10)
1. The casting method for the temperature-pressure flow multi-field cooperative control is characterized by comprising the following steps of:
setting a first temperature measuring point, a middle temperature measuring point and a last temperature measuring point on a die; the first temperature measuring point corresponds to a pouring position of the die, the middle temperature measuring point corresponds to at least part of structural mutation points in the die cavity, and the last temperature measuring point corresponds to the tail end of the die cavity;
pouring molten metal in the cavity, and applying casting pressure;
under the condition that the molten metal reaches the first temperature measuring point, the casting pressure is pressurized at a pressurizing rate of 2-5 mbar/s on the basis of the initial pressure, and the charging speed of the molten metal is controlled to be 0.84-2.1 cm/s;
under the condition that the intermediate temperature measuring point detects that the molten metal reaches a corresponding structure mutation point, increasing casting pressure and adjusting the mold filling speed; and along with the continuous increase of the distance between the middle temperature measuring point and the pouring position, the pressurizing rate of the casting pressure is gradually increased, and the filling speed is gradually increased;
the mold filling is completed until the last temperature measuring point detects that the molten metal reaches the tail end of the mold cavity, wherein the casting pressure when the molten metal reaches the tail end of the mold cavity is a first pressure, and the first pressure is 300 mbar/s-400 mbar/s;
and controlling the casting pressure to sequentially pressurize, maintain and release the pressure of the cavity on the basis of the first pressure to obtain the casting.
2. The casting method according to claim 1, wherein the intermediate temperature measurement points include a second temperature measurement point, a third temperature measurement point, and a fourth temperature measurement point, respectively, corresponding to the structural abrupt points that appear in sequence along the cavity;
under the condition that the intermediate temperature measuring point detects that the molten metal reaches the corresponding structure mutation point, increasing the casting pressure and adjusting the mold filling speed comprises the following steps:
under the condition that the second temperature measuring point detects the corresponding first pole, the casting pressure is boosted at a boosting rate of 2-15 mbar/s, and the filling speed of the molten metal is controlled to be 0.84-6.3 cm/s;
under the condition that the third temperature measuring point detects the corresponding first pole, the casting pressure is boosted at a boosting rate of 2-15 mbar/s, and the filling speed of the molten metal is controlled to be 0.84-6.3 cm/s;
under the condition that the fourth temperature measuring point detects the corresponding first pole, the casting pressure is boosted at a boosting rate of 2-15 mbar/s, and the filling speed of the molten metal is controlled to be 0.84-6.3 cm/s;
the first pole is the moment when the molten metal starts to shield the structure mutation point corresponding to the corresponding temperature measurement point.
3. The casting method according to claim 2, wherein the last temperature measurement point includes a fifth temperature measurement point, and the controlling the casting pressure to sequentially pressurize, maintain, and release the cavity based on the first pressure further includes:
under the condition that the fifth temperature measuring point detects the corresponding first pole, the casting pressure is pressurized to a second pressure for maintaining pressure under the condition that the pressurizing rate is 60 mbar/s-100 mbar/s, wherein the second pressure is 850 mbar-1500 mbar;
under the condition that the fourth temperature measuring point detects the corresponding second pole, adjusting the pressurizing rate to 50 mbar/s-80 mbar/s, pressurizing to third pressure, and maintaining the pressure, wherein the third pressure is 2500 mbar-3500 mbar;
under the condition that the second temperature measuring point detects a corresponding second pole, adjusting the pressurizing frequency to 40 mbar/s-60 mbar/s, pressurizing to fourth pressure, and maintaining the pressure, wherein the fourth pressure is 2500 mbar-3500 mbar;
releasing pressure to 0 under the condition that the first temperature measuring point detects a corresponding second pole;
the second pole is the moment when the corresponding molten metal starts to solidify at the corresponding temperature measuring point.
4. A casting method according to claim 3, characterized in that the initial pressure is 160-240 mbar.
5. The casting method according to claim 4, wherein the casting pressure is raised from 0mbar to 24mbar to the initial pressure at a pressurization rate of 16mbar/s to achieve a rise in the molten metal before the molten metal is detected to reach the first temperature measurement point.
6. The casting method according to claim 1, wherein the molten metal comprises an Al-Si-based cast nonferrous alloy, an Al-Cu-based cast nonferrous alloy, or an Al-Zn-based cast nonferrous alloy.
7. A casting method according to claim 3, wherein said releasing to 0 in case said first temperature measuring point detects a corresponding second pole comprises reducing said casting pressure to 0 at a reduced pressure rate of 200mbar/s to 400 mbar/s.
8. Use of the casting method according to any one of claims 1 to 7 in wheel casting.
9. The use of claim 8, wherein the cavity is a wheel casting cavity comprising a rim location and a spoke location, the first temperature measurement point corresponding to the casting location at the spoke location and being disposed at a flange connection of the spoke; the middle temperature measuring point comprises a second temperature measuring point, a third temperature measuring point and a fourth temperature measuring point;
the second temperature measuring point corresponds to a wall turning part of the spoke position;
the third temperature measuring point corresponds to the connecting turning thick wall of the spoke position and the rim position;
the fourth temperature measuring point corresponds to the connecting turning thin wall of the spoke position and the rim position;
and the last temperature measuring point corresponds to one end of the rim position far away from the pouring position.
10. The control device for controlling the temperature-pressure flow multi-field cooperative control is characterized in that the control device is applied to the casting method for controlling the temperature-pressure flow multi-field cooperative control according to any one of claims 1 to 7 or the application of the casting method according to any one of claims 8 to 9 in wheel casting, wherein the control device comprises:
the N temperature measuring devices are arranged corresponding to the first temperature measuring point, the middle temperature measuring point and the last temperature measuring point and are used for detecting the temperature of each temperature measuring point;
the first calculating mechanism is used for calculating the change rate of the temperature of each temperature measuring point along with time and determining that the corresponding temperature measuring point reaches the first pole under the condition that the change rate of the measured temperature of the nth temperature measuring device along with time is 0 for the first time; and determining that the corresponding temperature measuring point reaches the second pole under the condition that the change rate of the measured temperature of the nth temperature measuring device along with time is 0 again; wherein N is the serial number of N temperature measuring devices, N is more than 0 and less than or equal to N;
and the pressurizing parameter processor is in communication connection with the N temperature measuring devices and the first computing mechanism, and adjusts the pressurizing parameters according to the condition that each temperature measuring point reaches a standing point, wherein the pressurizing parameters comprise pressure, pressurizing rate and depressurizing rate.
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