CN117620090A - Production method of novel high-speed rail cast steel brake disc - Google Patents
Production method of novel high-speed rail cast steel brake disc Download PDFInfo
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- CN117620090A CN117620090A CN202311603587.0A CN202311603587A CN117620090A CN 117620090 A CN117620090 A CN 117620090A CN 202311603587 A CN202311603587 A CN 202311603587A CN 117620090 A CN117620090 A CN 117620090A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 50
- 229910001208 Crucible steel Inorganic materials 0.000 title claims abstract description 27
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 47
- 239000010959 steel Substances 0.000 claims abstract description 47
- 238000005266 casting Methods 0.000 claims abstract description 45
- 239000004576 sand Substances 0.000 claims abstract description 36
- 238000000034 method Methods 0.000 claims abstract description 27
- 238000007670 refining Methods 0.000 claims abstract description 20
- 239000000956 alloy Substances 0.000 claims abstract description 15
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 9
- 238000003723 Smelting Methods 0.000 claims abstract description 8
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 5
- 238000010438 heat treatment Methods 0.000 claims description 18
- 235000002245 Penicillium camembertii Nutrition 0.000 claims description 17
- 239000002893 slag Substances 0.000 claims description 12
- 239000011248 coating agent Substances 0.000 claims description 10
- 238000000576 coating method Methods 0.000 claims description 10
- 238000001816 cooling Methods 0.000 claims description 10
- 238000001035 drying Methods 0.000 claims description 10
- 238000000465 moulding Methods 0.000 claims description 10
- 238000007689 inspection Methods 0.000 claims description 9
- 238000003754 machining Methods 0.000 claims description 9
- 238000004140 cleaning Methods 0.000 claims description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 6
- 238000005422 blasting Methods 0.000 claims description 6
- 238000005187 foaming Methods 0.000 claims description 6
- 239000003973 paint Substances 0.000 claims description 6
- 239000000843 powder Substances 0.000 claims description 6
- 238000005496 tempering Methods 0.000 claims description 6
- 229910052845 zircon Inorganic materials 0.000 claims description 6
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 6
- 235000008733 Citrus aurantifolia Nutrition 0.000 claims description 3
- 244000035744 Hura crepitans Species 0.000 claims description 3
- 239000004793 Polystyrene Substances 0.000 claims description 3
- 235000011941 Tilia x europaea Nutrition 0.000 claims description 3
- 229910052786 argon Inorganic materials 0.000 claims description 3
- 238000007664 blowing Methods 0.000 claims description 3
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 claims description 3
- 230000006837 decompression Effects 0.000 claims description 3
- 239000000428 dust Substances 0.000 claims description 3
- 239000010436 fluorite Substances 0.000 claims description 3
- 230000006698 induction Effects 0.000 claims description 3
- 239000004571 lime Substances 0.000 claims description 3
- 229920002223 polystyrene Polymers 0.000 claims description 3
- 238000010791 quenching Methods 0.000 claims description 3
- 230000000171 quenching effect Effects 0.000 claims description 3
- 238000003756 stirring Methods 0.000 claims description 3
- 230000007547 defect Effects 0.000 abstract description 7
- 230000008602 contraction Effects 0.000 abstract description 3
- 239000011230 binding agent Substances 0.000 abstract 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 31
- 238000007528 sand casting Methods 0.000 description 4
- 238000005495 investment casting Methods 0.000 description 3
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 239000011324 bead Substances 0.000 description 2
- 238000013021 overheating Methods 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 241000221696 Sclerotinia sclerotiorum Species 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000006477 desulfuration reaction Methods 0.000 description 1
- 230000023556 desulfurization Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
Classifications
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
Abstract
The invention relates to the technical field of cast steel brake disc production, in particular to a production method of a high-speed rail cast steel brake disc, which comprises the following steps of 1) smelting molten steel; the molten steel for the high-speed rail brake disc is low-carbon and low-alloy wear-resistant steel, the molten steel is smelted by an intermediate frequency furnace and is subjected to LF refining, 2) a casting net shell production line is adopted to manufacture the high-speed rail cast steel brake disc, the molten steel for the high-speed rail brake disc is low-carbon and low-alloy wear-resistant steel, the molten steel is smelted by the intermediate frequency furnace and is subjected to LF refining and then poured, and the casting surface finish degree can be achieved through a novel net shell casting production line without using a traditional sand mold and a sand core: ra6.3-12.5um, the defects of sand holes and air holes are basically eliminated, the back sand is dry sand, no binder is contained, and the casting is solidified and contracted into ideal free contraction, so the dimensional accuracy of the produced cast steel brake disc is high and can reach: IT5-IT7 has small deformation, greatly reduces the defects of sand holes and air holes, freely contracts castings, completely eliminates the generation of cracks, greatly improves the process yield and the comprehensive yield, and opens up a new way for the production of high-speed rail brake discs.
Description
Technical Field
The invention relates to the technical field of cast steel brake disc production, in particular to a production method of a novel high-speed rail cast steel brake disc.
Background
Gao Tiezhu steel brake disc has extremely high requirements on casting quality, welding repair is not allowed, the traditional cast steel feeding process design is adopted at present, and a sand casting process for molding and core making by silica sand or precious pearl precoated sand is adopted, and because of the special structure of the cast steel brake disc, the feeding difficulty process has low yield and is difficult to exceed 50%; meanwhile, the magnetic mark crack is hardly completely eliminated due to the blocked shrinkage; the defects of sand holes and air holes are difficult to avoid, the comprehensive yield is low, and the total yield is difficult to exceed 90 percent. Some production enterprises adopt silica sol precision casting, the surface finish and the dimensional accuracy of the produced high-speed rail cast steel brake disc are high, but the production cost is high, the environment is seriously polluted, and the technical problems are not solved or alleviated.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a novel production method of a high-speed rail cast steel brake disc.
The purpose of the invention is realized in the following way: the production method of the novel high-speed rail cast steel brake disc comprises the following steps,
1) Smelting molten steel; the molten steel for the high-speed rail brake disc is low-carbon and low-alloy wear-resistant steel, and is smelted by an intermediate frequency furnace and refined by LF; the specific process is as follows:
adding scrap steel and alloy materials into an intermediate frequency furnace for induction heating, pouring the scrap steel and alloy materials into a ladle filled with premelted refining slag when the temperature of molten steel reaches 1640-1660 ℃, then moving the ladle into an LF refining furnace for heating, blowing argon into the ladle for stirring, simultaneously adding lime and fluorite to keep proper viscosity of the steel slag, adding a deoxidizer to make white slag, keeping the white slag for more than 15 minutes, removing the ladle from the LF refining furnace, feeding wires for deoxidization, and pouring at 1570-1590 ℃;
2) Manufacturing a high-speed rail cast steel brake disc by adopting a cast clean shell production line; the specific process is as follows:
white mold manufacturing, drying and drying; the white mold is made of high-density polystyrene through high-temperature foaming;
coating and hanging a shell; coating special high-strength zircon powder-based paint for multiple times, and drying and hardening at a low temperature of 50-80 ℃;
roasting the clean shell; roasting in a roasting furnace at 850-900 ℃ to remove the white mold;
filling sand and burying a shell for molding; after the shell is cooled, filling sand into a production line, boxing and embedding the shell, vacuumizing to 0.04-0.06Mpa, and hardening the sand mould;
pouring, namely pouring the refined molten steel at 1570-1590 ℃ in a shell, maintaining the pressure for 4-6 minutes, and releasing pressure;
shakeout cooling; decompression is carried out to remove shakeout after the flask is vacuumized, cooling is carried out, and the casting is cooled to room temperature;
cleaning castings; removing a pouring system and a riser, and cleaning the surface of the casting;
performing preliminary heat treatment; normalizing for 2-5 hours at 950-970 ℃ and tempering for 2-5 hours at 570-590 ℃;
rough machining and first inspection are carried out after shot blasting of castings; most of machining allowance is removed, and the nondestructive inspection surface requirement is met;
final heat treatment; quenching for X2-5 h at 930-950 ℃ and tempering for X2-5 h at 560-580 ℃;
and (5) performing finish machining after shot blasting again, and performing final inspection.
Preferably, the clean shell casting production line consists of white mold manufacturing, coating, hardening and shell manufacturing, roasting and removing of the clean shell of the white mold, a smelting unit, an automatic casting machine, a three-dimensional vibration molding table and sand spraying system, a 36-station circulating vacuum sand box line and a sand dust removing and cooling treatment system.
Preferably, the net shell casting process adopts special white mold zircon powder-based paint.
Preferably, the casting head system comprises a necking ball top heating riser, and the necking ball top heating riser adopts a point feeding theory.
The invention has the beneficial effects that: the production method of the novel high-speed rail cast steel brake disc adopts low-alloy wear-resistant steel composed of special components, the low-alloy wear-resistant steel is cast after being smelted by an intermediate frequency furnace and LF refined, the O content in refined molten steel is below 20ppm, the H content is below 1.0ppm, and the S content is below 0.01%; the inclusion content in the steel meets the specification of the ASTM standard grade 2.0 or more.
The net shell casting production line is adopted, sand mold and core are not used, sand holes and air holes are greatly reduced, the casting has shrinkage, the generation of cracks is thoroughly eliminated, the produced high-speed railway brake disc meets the requirements on various performance indexes, the surface finish Ra6.3-12.5um and the dimensional accuracy IT5-IT7 can reach the level close to the precision casting level of silica sol, the process yield and the comprehensive yield are greatly improved, and a new way is opened up for the production of the high-speed railway brake disc.
The process is used for manufacturing the cast steel brake disc blank, the traditional sand mould and sand core are not used, negative pressure molding is carried out, and the casting surface finish degree can be achieved: ra6.3-12.5um; the defects of sand holes and air holes are basically eliminated, the back sand is dry sand without adhesive, and the casting is solidified and contracted into ideal free contraction, so the dimensional accuracy of the produced cast steel brake disc is high and can be achieved: IT5-IT7, the deformation is small; far superior to the traditional sand casting.
The casting head system comprises a necking ball top heating riser, the necking ball top heating riser adopts a point feeding theory, namely, the inner diameter value of the neck of the riser is smaller than that of the top of the riser, overheating caused by increase of contact heat between the root of the riser and the riser can be avoided, the process yield is greatly improved, the knocking-off removal of the riser can be realized, the environment is protected, and the manufacturing cost is reduced.
Drawings
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, it being obvious that the drawings in the description below are only some embodiments of the invention, and that other drawings can be obtained according to these drawings without inventive faculty for a person skilled in the art.
Fig. 1 is a flow chart of a conventional sand casting process in the prior art.
FIG. 2 is a flow chart of the process of the invention for casting high-speed rail cast steel brake discs using a full-automatic casting net shell production line.
FIG. 3 is a process flow diagram of a fully automated net shell casting line of the present invention.
Description of the embodiments
The invention is further described with reference to fig. 1-3.
Examples
A production method of a novel high-speed rail cast steel brake disc comprises the following steps,
1) Smelting molten steel; the molten steel for the high-speed rail brake disc is low-carbon and low-alloy wear-resistant steel, and is smelted by an intermediate frequency furnace and refined by LF; the specific process is as follows:
adding scrap steel and alloy materials into an intermediate frequency furnace for induction heating, pouring the scrap steel and alloy materials into a ladle filled with premelted refining slag when the temperature of molten steel reaches 1640-1660 ℃, then moving the ladle into an LF refining furnace for heating, blowing argon into the ladle for stirring, simultaneously adding lime and fluorite to keep proper viscosity of the steel slag, adding a deoxidizer to make white slag, keeping the white slag for more than 15 minutes, removing the ladle from the LF refining furnace, feeding wires for deoxidization, and pouring at 1570-1590 ℃; the high-quality pure molten steel can be obtained through an intermediate frequency furnace and LF refining process.
The O content in the refined molten steel is below 20ppm, the H content is below 1.0ppm, and the S content is below 0.01%; the inclusion content in the steel accords with the specification of the ASTM standard grade 2.0 or more;
2) Manufacturing a high-speed rail cast steel brake disc by adopting a full-automatic casting clean shell production line; the specific process is as follows:
white mold manufacturing, drying and drying; the white mold is made of high-density polystyrene through high-temperature foaming;
coating and hanging a shell; coating special high-strength zircon powder-based paint for multiple times, and drying and hardening at a low temperature of 50-80 ℃;
roasting the clean shell; roasting in a roasting furnace at 850-900 ℃ to remove the white mold;
filling sand and burying a shell for molding; after the shell is cooled, filling sand into a production line, boxing and embedding the shell, vacuumizing to 0.04-0.06Mpa, and hardening the sand mould;
pouring, namely pouring the refined molten steel at 1570-1590 ℃ in a shell, maintaining the pressure for 4-6 minutes, and releasing pressure;
shakeout cooling; and (5) removing shakeout after the flask is subjected to vacuum by decompression, cooling, and cooling the casting to room temperature.
Cleaning castings; and removing the pouring system and the riser, and cleaning the surface of the casting.
Performing preliminary heat treatment; normalizing for 2-5 hours at 950-970 ℃ and tempering for 2-5 hours at 570-590 ℃;
rough machining and first inspection are carried out after shot blasting of castings; most of machining allowance is removed, and the nondestructive inspection surface requirement is met.
Final heat treatment; quenching for X2-5 h at 930-950 ℃ and tempering for X2-5 h at 560-580 ℃.
Finish machining is carried out after shot blasting cleaning again, and final inspection is carried out;
the process is used for manufacturing the cast steel brake disc blank, the traditional sand mould and sand core are not used, negative pressure molding is carried out, and the casting surface finish degree can be achieved: ra6.3-12.5um; the defects of sand holes and air holes are basically eliminated, the back sand is dry sand without adhesive, and the casting is solidified and contracted into ideal free contraction, so the dimensional accuracy of the produced cast steel brake disc is high and can be achieved: IT5-IT7, the deformation is small; far superior to the traditional sand casting.
The low-alloy wear-resistant steel is a steel grade developed on the basis of low-alloy high-strength welding steel, and has the characteristics of high hardness, good toughness and wear resistance.
In the embodiment, the full-automatic clean shell casting production line consists of a smelting unit, an automatic casting machine, a three-dimensional vibration molding table, a sand scattering system, a 36-station circulating vacuum sand box line, sand dust removal and cooling treatment systems, wherein the smelting unit is an intermediate frequency furnace and an LF refining furnace, and the method is a ladle refining method for carrying out secondary refining by feeding molten steel melted by the intermediate frequency electric furnace into the LF refining furnace and adopting a duplex method. The molten steel refining process of the LF refining furnace is one of the most important methods for improving the purity of molten steel and the internal quality of castings, and has the characteristics of strong refining capability, deoxidization, desulfurization, inclusion removal and good molten steel purifying effect. The granularity of the foaming material is controlled to be 0.3-0.8mm, and the high-density 28-32g/L white mould is prepared to replace Dan Lamo; low cost, small deformation and compact and smooth surface.
As shown in fig. 3, the process flow of the net shell casting production line is as follows: the EPS beads are subjected to pre-foaming, curing and pattern forming foaming treatment, the surfaces are treated after drying, then the EPS beads are assembled, the shells are manufactured through a 3-5-layer coating composite process, the shells are baked, the shells are lost in a die mode, the shells are cooled, the production line is filled with sand, the shells are embedded into boxes, the vacuum pumping is carried out for sand mold solidification, molten steel is poured into the shells after refining, and finally the shells are cooled, shakeout and opened. Adopting a clean shell casting production line, and integrating white mold molding without sand mold and core and parting line and flash; the defects of sand holes and air holes are greatly reduced, the casting has shrinkage, the generation of cracks is thoroughly eliminated, the produced high-speed railway brake disc not only meets the requirements on various performance indexes, but also has the surface finish of Ra6.3-12.5um and the dimensional accuracy IT5-IT7, which can reach the precision casting level close to silica sol, greatly improves the process yield and the comprehensive yield, and opens up a new way for the production of the high-speed railway brake disc.
In the embodiment, the clean shell casting process adopts special white mold zircon powder-based paint, has no volatile odor, environmental protection, good coating performance, smooth surface, good low-temperature hardening performance, high strength of the calcined shell, good air permeability and no cracking.
In this embodiment, the casting and riser system comprises a necking ball top heating riser, the necking ball top heating riser adopts a point feeding theory, namely, the inner diameter value of the neck of the riser is smaller than that of the top of the riser, so that overheating caused by increase of contact heat between the root of the riser and the riser can be avoided, the process yield is greatly improved, the riser knock-off and removal can be realized, the environment is protected, and the manufacturing cost is reduced.
The above examples illustrate only one embodiment of the invention, which is described in more detail and is not to be construed as limiting the scope of the invention. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the invention, which are all within the scope of the invention. Accordingly, the scope of protection of the present invention is to be determined by the appended claims.
Claims (4)
1. A production method of a novel high-speed rail cast steel brake disc is characterized by comprising the following steps of,
1) Smelting molten steel; the molten steel for the high-speed rail brake disc is low-carbon and low-alloy wear-resistant steel, and is smelted by an intermediate frequency furnace and refined by LF; the specific process is as follows:
adding scrap steel and alloy materials into an intermediate frequency furnace for induction heating, pouring the scrap steel and alloy materials into a ladle filled with premelted refining slag when the temperature of molten steel reaches 1640-1660 ℃, then moving the ladle into an LF refining furnace for heating, blowing argon into the ladle for stirring, simultaneously adding lime and fluorite to keep proper viscosity of the steel slag, adding a deoxidizer to make white slag, keeping the white slag for more than 15 minutes, removing the ladle from the LF refining furnace, feeding wires for deoxidization, and pouring at 1570-1590 ℃;
2) Manufacturing a high-speed rail cast steel brake disc by adopting a cast clean shell production line; the specific process is as follows:
white mold manufacturing, drying and drying; the white mold is made of high-density polystyrene through high-temperature foaming;
coating and hanging a shell; coating special high-strength zircon powder-based paint for multiple times, and drying and hardening at a low temperature of 50-80 ℃;
roasting the clean shell; roasting in a roasting furnace at 850-900 ℃ to remove the white mold;
filling sand and burying a shell for molding; after the shell is cooled, filling sand into a production line, boxing and embedding the shell, vacuumizing to 0.04-0.06Mpa, and hardening the sand mould;
pouring, namely pouring the refined molten steel at 1570-1590 ℃ in a shell, maintaining the pressure for 4-6 minutes, and releasing pressure;
shakeout cooling; decompression is carried out to remove shakeout after the flask is vacuumized, cooling is carried out, and the casting is cooled to room temperature;
cleaning castings; removing a pouring system and a riser, and cleaning the surface of the casting;
performing preliminary heat treatment; normalizing for 2-5 hours at 950-970 ℃ and tempering for 2-5 hours at 570-590 ℃;
rough machining and first inspection are carried out after shot blasting of castings; most of machining allowance is removed, and the nondestructive inspection surface requirement is met;
final heat treatment; quenching for X2-5 h at 930-950 ℃ and tempering for X2-5 h at 560-580 ℃;
and (5) performing finish machining after shot blasting again, and performing final inspection.
2. The production method of the novel high-speed rail cast steel brake disc according to claim 1, wherein the clean shell casting production line consists of white mold manufacturing, coating, hardening and shell manufacturing, roasting and removing of white mold clean shells, smelting units, an automatic casting machine, a three-dimensional vibration molding table and sanding system, a 36-station circulating vacuum sand box line, sand dust removal and cooling treatment system.
3. The method for producing a novel high-speed rail cast steel brake disc according to claim 1, wherein the net shell casting process adopts special white mold zircon powder-based paint.
4. The method for producing the novel high-speed rail cast steel brake disc according to claim 1, wherein the casting head system comprises a necking ball top exothermic riser, and the necking ball top exothermic riser adopts a point feeding theory.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311603587.0A CN117620090A (en) | 2023-11-28 | 2023-11-28 | Production method of novel high-speed rail cast steel brake disc |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311603587.0A CN117620090A (en) | 2023-11-28 | 2023-11-28 | Production method of novel high-speed rail cast steel brake disc |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117620090A true CN117620090A (en) | 2024-03-01 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311603587.0A Pending CN117620090A (en) | 2023-11-28 | 2023-11-28 | Production method of novel high-speed rail cast steel brake disc |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN117620090A (en) |
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- 2023-11-28 CN CN202311603587.0A patent/CN117620090A/en active Pending
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