CN117920976A - Open type anti-gravity filling solidification device and filling solidification method using same - Google Patents
Open type anti-gravity filling solidification device and filling solidification method using same Download PDFInfo
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Abstract
The invention provides an open type anti-gravity filling type solidification device and a filling type solidification method using the same; the open type anti-gravity filling solidification device comprises a smelting furnace, a crucible, a furnace cover, a liquid lifting pipe, a filling stop contact, a top contact, a gradient contact, a forced pressure release contact and an open type casting mold. The open type anti-gravity filling and solidifying method using the open type anti-gravity filling and solidifying device comprises the following steps and contents: step 1, equipment installation; step 2, air inlet filling; step 3, pressure relief and filling; and 4, maintaining pressure and solidifying. The casting mold disclosed by the invention can ensure the alloy quality in the casting cavity, can realize stable mold filling and bottom gate feeding in the solidification process of the casting, improves the casting quality, simultaneously remarkably improves the casting mold exhaust capacity, eliminates the back pressure of the cavity, ensures the complete formation of the casting, and avoids the defect that air enters the alloy to form air holes. The invention has high production efficiency, stability and safety.
Description
Technical Field
The invention relates to the technical field of structural design and antigravity casting of antigravity casting equipment, in particular to an open antigravity filling solidification device and a filling solidification method using the same.
Background
With antigravity casting, a casting and pouring process was developed in the 50 s of the 20 th century. The method is a method for filling casting mould along the liquid lifting pipe from bottom to top under the action of pressure to overcome gravity and other resistance and obtain casting under pressure. According to the pressure applied by the molten metal filling mold, the antigravity casting can be classified into low pressure casting, differential pressure casting, pressure regulating casting, vacuum suction casting, and the like. The anti-gravity casting technology can extract pure alloy liquid from the middle part of the crucible to stably fill the casting cavity, simultaneously solidify the whole casting mould under the action of external force, and improve the casting quality.
The conventional method is to push alloy liquid to rise from the center of a crucible along a liquid lifting pipe through an air pressure or mechanical pump, and stop air inlet after entering a cavity to reach a top contact of a mold so as to finish mold filling. However, as the viscosity of the alloy liquid is greatly influenced by a temperature field in the mold filling process, when the alloy liquid flows through a filter screen, a thin-wall cavity and a complex structure, large resistance exists, the rising speed is slowed down, so that deviation exists between the pressure in the smelting furnace and the actual liquid level height conversion, and further, after the alloy liquid reaches a top contact point, the pressure in the smelting furnace is too high, if an open casting mold is adopted, a large amount of alloy liquid is sprayed out from a riser, so that a large amount of alloy liquid is wasted, and the safety of equipment and personnel is seriously influenced.
Therefore, the casting mould adopted by various casting antigravity casting equipment in China is a closed cavity, alloy liquid is prevented from overflowing, but the top of the casting mould needs to be covered before pouring, the cost is increased, the casting ladle liquid can not be used for feeding liquid to a riser in the solidification process, and the feeding efficiency is low because the flowing distance and the temperature are long at the top. Meanwhile, the upper part is closed, the exhaust capacity of the casting mould is severely limited, after the high-temperature alloy liquid is contacted with the sand mould in the casting process, a large amount of gas generated by decomposition of the resin curing agent in the sand mould cannot be discharged, so that the pressure of a cavity is rapidly increased, the filling capacity of the alloy liquid is reduced, cold insulation defects are easily formed in the thin-wall complex structural area of the casting, and part of gas breaks through the alloy surface layer and enters the casting to form air hole defects. In addition, most of gases generated after the resin and the curing agent in the sand core are decomposed are combustible gases, so that the concentration of the combustible gases in the cavity is rapidly increased in the casting process, and the safety risk exists under the high-temperature effect.
Therefore, an open type anti-gravity filling solidification device and method are needed, the requirements of complete forming and quality control of the casting with the complex structure are met, and the production safety is ensured.
Disclosure of Invention
The invention provides an open type antigravity filling solidification device and method, which mainly adopts an antigravity mode to continuously convey alloy liquid to a cavity of an open casting mold 9 until reaching the top of an open type riser 92, and maintains the alloy liquid in the cavity to be suspended until solidification by adopting methods of air inlet filling, pressure relief filling and suspension pressure maintaining.
The technical scheme of the invention is as follows:
An open type antigravity filling type solidification device is technically characterized in that: the device comprises a smelting furnace 1, a crucible 2, a furnace cover 3, a liquid lifting pipe 4, a filling stop contact 5, a top contact 6, a gradient contact 7, a forced pressure release contact 8, an open casting mold 9 and a control cabinet; wherein: crucible 2 is placed in smelting furnace 1, furnace body installation admission valve 17 and discharge valve 18, bell 3 are installed in smelting furnace 1 top, and stalk 4 is installed on bell 3, and open casting mould 9 is wholly placed in stalk 4 and bell 3 top.
The open type anti-gravity filling type solidification device has the following technical contents:
The furnace cover 3 and the flange of the smelting furnace 1 are provided with a sealing groove 11, graphite packing or asbestos packing can be placed in the sealing groove 11 for sealing, a plurality of lift tube mounting platforms 12 are designed on the furnace cover 3, when the lift tube 4 is not placed, sealing is carried out by adopting a steel circular plate 13 with the same area, and a trapezoid steel choke ring 14 is designed on the periphery of the lift tube 4 mounting platform.
An asbestos pad 15 is arranged between the flange bottom surface of the liquid lifting pipe 4 and the center of the furnace cover 3, and is connected and sealed by bolts; tightening and sealing bolts, and adopting a conventional connecting method;
For high-capacity casting, 1 to 10 liquid lifting pipes 4 are adopted to cast simultaneously at a plurality of straight pouring gate 91 points set below the casting mould 9.
The top of the casting mould 9 is not closed, the riser 92 is of an open design, a fireproof layer 93 with the thickness of 100-500 mm is arranged at the top of all the risers 92, a flow blocking groove 95 is arranged at the bottom of the casting mould 9, the flow blocking groove 95 is matched with the flow blocking ring 14 of the furnace cover 3 to be positioned and prevent alloy liquid from flowing out from the bottom, an asbestos pad 15 is arranged between the vicinity of the sprue 91 of the casting mould 9 and the upper plane of the flange of the riser tube 4, and the casting mould 9 is sealed by dead weight or weight compaction is arranged above the casting mould 9.
The charging type stop contact 5, the top contact 6, the gradient contact 7 and the forced pressure release contact 8 are all wrapped by boron nitride BN or aluminum oxide Al 2O3 high-strength heat-resistant insulating ceramic tubes;
The ceramic tube is flush with the wall of the casting mold 9, the center contact extends out of the section of the ceramic tube for 1-2 mm, the filling stop contact 5 is arranged in the open casting mold 9, the top contact 6 is arranged at the top of a riser 92 of the open casting mold 9, the gradient contact 7 and the forced pressure release contact 8 are arranged in the fireproof layer 93 in a gradient manner, and all electromagnetic valves and contacts of the whole device are connected with the equipment control cabinet. The ceramic tube ensures that the contact cannot be conducted before contacting the alloy liquid, so that an error sending electric signal is avoided, and meanwhile, after contacting the alloy liquid, the contact can be smoothly taken out after the alloy is solidified, so that the contact can be reused.
The filling type stop contact 5 is arranged at the 1/5-1/2 position of the height of the riser 92 at the top of the open casting mold 9, the filling type stop contact 6 is arranged at the top of the riser 92, 3-10 gradient contacts 7 are arranged in the fireproof layer 93 above the riser 92 and are respectively numbered as L 1～Ln, the same height is arranged in a gradient manner at intervals, the interval height H=10-200 mm, and the forced pressure relief contact 8 is arranged at the top of the fireproof layer 93. The innovation point is that through the operation, gradient pressure relief is realized, the alloy liquid is ensured to stably stay in the height range of the fireproof layer 93 and does not overshoot, and under the condition that the whole riser is opened finally, the alloy liquid is stably filled and solidified in an antigravity mode.
The open type anti-gravity filling and solidifying method using the open type anti-gravity filling and solidifying device comprises the following steps and contents in sequence:
step 1, equipment installation: after the alloy smelting is completed, a furnace cover 3 is covered, and bolts are screwed for sealing; according to the position of a sprue 91 of the open casting mold 9, opening a steel circular plate 13 above a corresponding lift tube 4 mounting platform, inserting the lift tube 4, and then screwing a flange bolt of the lift tube 4, so as to ensure the tightness between the bottom surface of the flange of the lift tube 4 and the mounting platform; placing a filter screen and an asbestos pad 15 on the upper plane of a flange of the lift tube 4, aligning the centers of a flow blocking groove 95 at the bottom of the open casting mold 9 and a flow blocking ring 14 of the furnace cover 3, placing the mold above the furnace cover 3 and the lift tube 4, and compacting the asbestos pad 15 to realize sealing; the charging type stop contact 5, the top contact 6, the gradient contact 7 and the forced pressure release contact 8 are respectively connected with a control silicon wire;
step 2, air inlet filling: the control cabinet controls the air inlet valve 17 to be opened, compressed air is introduced into the smelting furnace 1, alloy liquid is pushed to enter the cavity of the open casting mold 9 through the liquid lifting pipe 4, after the alloy liquid reaches the root of the riser 92, the filling stop contact 5 is connected, the control cabinet closes the air inlet valve 17, and air inlet is stopped;
step 3, pressure relief and filling: after the air inlet is stopped, the air pressure in the smelting furnace 1 pushes the alloy liquid to continuously rise, and finally the alloy liquid is continuously risen, after reaching the top of the riser 92, the top contact 6 is connected, and the control cabinet controls the exhaust valve 18 to be opened; the pressure release is completed once according to a set value P 0, wherein P0 is empirical data obtained according to experiments, and manual setting is required according to different casting structures, pouring systems and casting process parameters; if the alloy liquid continues to rise in the fireproof layer 93, the alloy liquid rises until the liquid level above the alloy liquid enters the fireproof layer 93; the gradient contacts 71-n are sequentially communicated, and the control cabinet performs gradient pressure relief according to a set gradient value P 1, namely when the gradient contact 7n is connected, the automatic pressure relief value is n multiplied by P 1 until the alloy liquid does not rise any more and hovers above the top contact 6. The equal heights are distributed at intervals, the relation between the set value P 1 and the interval height H is P1=0.5-1 rhogH, so that when the alloy liquid level reaches the nth contact, the maximum descending distance of the alloy liquid level can not exceed n×H after the pressure of n×P1 is removed, namely the liquid level height cannot be lower than the top height, and the complete filling of the casting is ensured;
And step 4, pressure maintaining and solidification: after the aluminum liquid hovers, the control cabinet controls the air inlet valve 17 to be intermittently opened and closed, the air pressure in the smelting furnace 1 is kept constant, and the up-down floating error is within +/-1 KPa until the alloy is solidified in the cavity of the casting mould 9; finally, the aluminum alloy casting which is solidified through open type antigravity filling is obtained.
The relation between the interval height H of the gradient contact 7 and the alloy liquid density rho, the gravity acceleration g and the gradient pressure release value P 1 is P 1 = (0.5-1.5) rhogH.
As the preferable scheme, the filling type stop contact 5, the type top contact 6, the gradient contact 7 and the forced pressure relief contact 8 can be wrapped by a thin-wall high-strength heat-resistant insulating ceramic tube with the inner diameter of 0.1-2 mm and then are arranged at the fixed position of the metal casting mold 9, only the contact end of 0.1-0.5 mm stretches into the cavity to be in contact with alloy liquid in the filling process, after the filling is completed, the casting is laterally taken out and the contact end is cleaned, so that the contact can be reused, and the repeated reuse requirement of the metal mold automatic batch production process is met.
In summary, the open type anti-gravity filling solidification device comprises a smelting furnace 1, a crucible 2, a furnace cover 3, a liquid lifting pipe 4, a filling stop contact 5, a forming top contact 6, a gradient contact 7, a forced pressure relief contact 8 and an open type casting mold 9. The technical route adopted by the invention is as follows: after alloy smelting is completed, compressed gas is introduced into the smelting furnace 1, alloy liquid is conveyed into the casting mold 9 along the mouth of the liquid lifting pipe 4, after the alloy liquid level in the casting mold 9 reaches the mold filling stop contact 5, air inflow is stopped, the alloy liquid continuously rises under the action of internal pressure difference of the furnace, after reaching the mold top contact 6, certain air pressure in the furnace is removed, if the alloy liquid still continuously rises, the gradient contact 7 is lighted step by step, the internal pressure of the furnace is removed in sections according to different pressure relief values until the alloy liquid level is stable, pressure is continuously maintained until a casting is solidified, and if the alloy liquid continuously rises to the forced pressure relief contact 8, all air pressure in the furnace is forcibly removed, and personnel and equipment safety is ensured.
The beneficial effects of the invention are as follows:
according to the invention, the open casting mold 9 is adopted for anti-gravity filling solidification, so that the alloy quality entering the interior of the casting cavity can be ensured, the casting is stably filled and bottom gate feeding in the solidification process can be realized, the casting quality is improved, the exhaust capacity of the casting mold 9 is obviously improved, the back pressure of the cavity is eliminated, the complete formation of the casting is ensured, and the defect that air holes are formed in the alloy is avoided when air enters the interior of the casting. The open type antigravity filling type solidification method provided by the invention has the advantages that the whole flow is full-automatic unmanned operation, and the production efficiency, the stability and the safety are high. The open casting mold 9 can be a sand mold or a metal mold, and can realize automatic batch production of the metal mold.
According to the technical scheme, the open casting mold 9 is adopted for performing anti-gravity mold filling solidification, so that the quality of alloy entering the casting cavity is guaranteed, stable mold filling of the casting and bottom gate feeding in the solidification process can be realized, the quality of the casting is improved, the exhaust capacity of the casting mold 9 is remarkably improved, the back pressure of the cavity is eliminated, the complete formation of the casting is guaranteed, and the defect that air holes are formed in the alloy due to the fact that air enters the casting is avoided. The open type filling casting can be applied to sand molds and shell molds as well as metal molds, each contact can be repeatedly reused, reconnection is not needed, the whole process is full-automatic unmanned operation, and the production efficiency, stability and safety are high.
Drawings
FIG. 1 is a block diagram of an open-type antigravity-filling coagulation apparatus according to the invention;
FIG. 2 is a partial sectional view of the open mold 9;
fig. 3 is a partial enlarged view of a contact mounting area;
FIG. 4 is a schematic view of the whole structure of the smelting furnace 1;
FIG. 5 is a sectional view of smelting furnace 1;
fig. 6 is a partial cross-sectional view of the area of the lift tube 4.
Detailed Description
The invention is further illustrated, but not limited, by the following examples and figures of the specification.
Example 1
An open type antigravity filling type solidification device is shown in fig. 1-6; the device comprises a smelting furnace 1, a crucible 2, a furnace cover 3, a liquid lifting pipe 4, a filling stop contact 5, a top contact 6, a gradient contact 7, a forced pressure release contact 8, an open casting mold 9 and a control cabinet; wherein: crucible 2 is placed in smelting furnace 1, furnace body installation admission valve 17 and discharge valve 18, bell 3 are installed in smelting furnace 1 top, and stalk 4 is installed on bell 3, and open casting mould 9 is wholly placed in stalk 4 and bell 3 top.
The furnace cover 3 and the flange of the smelting furnace 1 are provided with a sealing groove 11, graphite packing or asbestos packing can be placed in the sealing groove 11 for sealing, a plurality of lift tube mounting platforms 12 are designed on the furnace cover 3, when the lift tube 4 is not placed, sealing is carried out by adopting a steel circular plate 13 with the same area, and a trapezoid steel choke ring 14 is designed on the periphery of the lift tube 4 mounting platform.
An asbestos pad 15 is arranged between the flange bottom surface of the liquid lifting pipe 4 and the center of the furnace cover 3, and is connected and sealed by bolts; tightening and sealing bolts, and adopting a conventional connecting method;
For high-capacity casting, 1 to 10 liquid lifting pipes 4 are adopted to cast simultaneously at a plurality of straight pouring gate 91 points set below the casting mould 9.
The top of the casting mould 9 is not closed, the riser 92 is of an open design, a fireproof layer 93 with the thickness of 100-500 mm is arranged at the top of all the risers 92, a flow blocking groove 95 is arranged at the bottom of the casting mould 9, the flow blocking groove 95 is matched with the flow blocking ring 14 of the furnace cover 3 to be positioned and prevent alloy liquid from flowing out from the bottom, an asbestos pad 15 is arranged between the vicinity of the sprue 91 of the casting mould 9 and the upper plane of the flange of the riser tube 4, and the casting mould 9 is sealed by dead weight or weight compaction is arranged above the casting mould 9.
The charging type stop contact 5, the top contact 6, the gradient contact 7 and the forced pressure release contact 8 are all wrapped by boron nitride BN or aluminum oxide Al 2O3 high-strength heat-resistant insulating ceramic tubes;
The ceramic tube is flush with the wall of the casting mold 9, the center contact extends out of the section of the ceramic tube for 1-2 mm, the filling stop contact 5 is arranged in the open casting mold 9, the top contact 6 is arranged at the top of a riser 92 of the open casting mold 9, the gradient contact 7 and the forced pressure release contact 8 are arranged in the fireproof layer 93 in a gradient manner, and all electromagnetic valves and contacts of the whole device are connected with the equipment control cabinet. The ceramic tube ensures that the contact cannot be conducted before contacting the alloy liquid, so that an error sending electric signal is avoided, and meanwhile, after contacting the alloy liquid, the contact can be smoothly taken out after the alloy is solidified, so that the contact can be reused.
The filling type stop contact 5 is arranged at the 1/5-1/2 position of the height of the riser 92 at the top of the open casting mold 9, the filling type stop contact 6 is arranged at the top of the riser 92, 3-10 gradient contacts 7 are arranged in the fireproof layer 93 above the riser 92 and are respectively numbered as L 1～Ln, the same height is arranged in a gradient manner at intervals, the interval height H=10-200 mm, and the forced pressure relief contact 8 is arranged at the top of the fireproof layer 93. The innovation point is that through the operation, gradient pressure relief is realized, the alloy liquid is ensured to stably stay in the height range of the fireproof layer 93 and does not overshoot, and under the condition that the whole riser is opened finally, the alloy liquid is stably filled and solidified in an antigravity mode.
Example 2
The open type antigravity filling and solidifying method using the open type antigravity filling and solidifying device described in the embodiment 1, the specific process sequentially comprises the following steps and contents:
step 1, equipment installation: after the alloy smelting is completed, a furnace cover 3 is covered, and bolts are screwed for sealing; according to the position of a sprue 91 of the open casting mold 9, opening a steel circular plate 13 above a corresponding lift tube 4 mounting platform, inserting the lift tube 4, and then screwing a flange bolt of the lift tube 4, so as to ensure the tightness between the bottom surface of the flange of the lift tube 4 and the mounting platform; placing a filter screen and an asbestos pad 15 on the upper plane of a flange of the lift tube 4, aligning the centers of a flow blocking groove 95 at the bottom of the open casting mold 9 and a flow blocking ring 14 of the furnace cover 3, placing the mold above the furnace cover 3 and the lift tube 4, and compacting the asbestos pad 15 to realize sealing; the charging type stop contact 5, the top contact 6, the gradient contact 7 and the forced pressure release contact 8 are respectively connected with a control silicon wire;
step 2, air inlet filling: the control cabinet controls the air inlet valve 17 to be opened, compressed air is introduced into the smelting furnace 1, alloy liquid is pushed to enter the cavity of the open casting mold 9 through the liquid lifting pipe 4, after the alloy liquid reaches the root of the riser 92, the filling stop contact 5 is connected, the control cabinet closes the air inlet valve 17, and air inlet is stopped;
step 3, pressure relief and filling: after the air inlet is stopped, the air pressure in the smelting furnace 1 pushes the alloy liquid to continuously rise, and finally the alloy liquid is continuously risen, after reaching the top of the riser 92, the top contact 6 is connected, and the control cabinet controls the exhaust valve 18 to be opened; the pressure release is completed once according to a set value P 0, wherein P0 is empirical data obtained according to experiments, and manual setting is required according to different casting structures, pouring systems and casting process parameters; if the alloy liquid continues to rise in the fireproof layer 93, the alloy liquid rises until the liquid level above the alloy liquid enters the fireproof layer 93; the gradient contacts 71-n are sequentially communicated, and the control cabinet performs gradient pressure relief according to a set gradient value P 1, namely when the gradient contact 7n is connected, the automatic pressure relief value is n multiplied by P 1 until the alloy liquid does not rise any more and hovers above the top contact 6. The equal heights are distributed at intervals, the relation between the set value P 1 and the interval height H is P1=0.5-1 rhogH, so that when the alloy liquid level reaches the nth contact, the maximum descending distance of the alloy liquid level can not exceed n×H after the pressure of n×P1 is removed, namely the liquid level height cannot be lower than the top height, and the complete filling of the casting is ensured;
And step 4, pressure maintaining and solidification: after the aluminum liquid hovers, the control cabinet controls the air inlet valve 17 to be intermittently opened and closed, the air pressure in the smelting furnace 1 is kept constant, and the up-down floating error is within +/-1 KPa until the alloy is solidified in the cavity of the casting mould 9; finally, the aluminum alloy casting which is solidified through open type antigravity filling is obtained.
The relation between the interval height H of the gradient contact 7 and the alloy liquid density rho, the gravity acceleration g and the gradient pressure release value P 1 is P 1 = (0.5-1.5) rhogH.
The filling type stop contact 5, the type top contact 6, the gradient contact 7 and the forced pressure release contact 8 can be wrapped by a thin-wall high-strength heat-resistant insulating ceramic tube with the inner diameter of 0.1-2 mm and then placed at the fixed position of the metal casting mold 9, only the contact end of 0.1-0.5 mm stretches into the cavity to be in contact with alloy liquid in the filling process, after the filling is completed, the casting is laterally taken out and the contact end is cleaned, so that the contact can be reused, and the requirement of repeated reuse in the metal mold automatic batch production process is met.
Example 3
A certain space aluminum alloy casting sand mold antigravity filling suspension solidification process; the specific process is as follows:
Step 1, equipment installation: after the alloy smelting is completed, the furnace cover 3 is covered, the bolt is screwed up for sealing, according to the position of a sprue 91 of the open casting mold 9, 3 steel circular plates 13 are arranged above a mounting platform of the liquid lifting pipe 4 in total at the center and the two ends, flange bolts of the liquid lifting pipe 4 are screwed up after the liquid lifting pipe 4 is inserted, the tightness between the flange bottom surface of the liquid lifting pipe 4 and the mounting platform is ensured, a filter screen and an asbestos pad 15 are placed on the upper plane of the flange of the liquid lifting pipe 4, after the centers of a flow blocking groove 95 at the bottom of the open casting mold 9 and a flow blocking ring 14 of the furnace cover 3 are aligned, the filter screen and the asbestos pad 15 are placed above the furnace cover 3 and the liquid lifting pipe 4, sealing is realized, and a filling stop contact 5, a top contact 6, a gradient contact 7 and a forced pressure release contact 8 are respectively connected with a control cabinet through wires.
Step 2, air inlet filling: the control cabinet controls the opening of the air inlet valve 17, compressed air is introduced into the smelting furnace 1 according to the boosting speed of 1.5KPa/s, alloy liquid is pushed to enter the cavity of the open casting mold 9 through the liquid lifting pipe 4, after the alloy liquid reaches the root of the riser 92, the filling stop contact 5 is connected, the control cabinet closes the air inlet valve 17, and air inlet is stopped;
step 3, pressure relief and filling: after the air intake is stopped, the air pressure in the smelting furnace 1 pushes the alloy liquid to continuously rise, the alloy liquid is finally continuously risen, after reaching the top of the riser 92, the top contact 6 is connected, the control cabinet controls the exhaust valve 18 to be opened, the pressure is released by 4KPa, if the alloy liquid continuously rises in the fireproof layer 93, the gradient contacts 7L 1～L5 are sequentially communicated with the adjacent gradient contacts 7 at intervals of 40mm in height, the control cabinet respectively carries out automatic gradient pressure release according to the gradient value of 0.5KPa until the alloy liquid is not risen any more, and the alloy liquid hovers above the top contact 6;
and step 4, pressure maintaining and solidification: after the aluminum liquid hovers, the control cabinet controls the air inlet valve 17 to be intermittently opened and closed, the air pressure in the smelting furnace 1 is kept constant, and the up-down floating error is within +/-1 KPa until the alloy is solidified in the cavity of the casting mould 9.
Example 4
The embodiment is a metal type antigravity filling type suspension solidification process of an aluminum alloy cross beam for a certain vehicle.
The specific process is as follows:
Step 1, equipment installation: after alloy smelting is completed, a furnace cover 3 is covered, a bolt is screwed up for sealing, a circular plate 13 is made of steel above a mounting platform of a central riser tube 4 according to the position of a sprue 91 of an open casting mold 9, flange bolts of the riser tube 4 are screwed up after the riser tube 4 is inserted, tightness between the flange bottom surface of the riser tube 4 and the mounting platform is guaranteed, a filter screen and an asbestos pad 15 are placed on the upper plane of the flange of the riser tube 4, a bottom blocking groove 95 of the open casting mold 9 is aligned with the center of a blocking ring 14 of the furnace cover 3, and then placed above the furnace cover 3 and the riser tube 4, the asbestos pad 15 is tightly pressed, sealing is achieved, a filling type stop contact 5, a type top contact 6, a gradient contact 7 and a forced pressure release contact 8 are wrapped by adopting a thin-wall high-strength heat-resistant insulating ceramic tube with the inner diameter of 2mm, and then the sealing position is placed in a fixed position of the metal casting mold 9, and only the contact end 0.5mm stretches into a cavity, and the filling type stop contact 5, the gradient contact 7 and the forced pressure release contact 8 are respectively connected with a control cabinet wire.
Step 2, air inlet filling: the control cabinet controls the opening of the air inlet valve 17, compressed air is introduced into the smelting furnace 1 according to the boosting speed of 1.5KPa/s, alloy liquid is pushed to enter the cavity of the open casting mold 9 through the liquid lifting pipe 4, after the alloy liquid reaches the root of the riser 92, the filling stop contact 5 is connected, the control cabinet closes the air inlet valve 17, and air inlet is stopped;
step 3, pressure relief and filling: after the air intake is stopped, the air pressure in the smelting furnace 1 pushes the alloy liquid to continuously rise, the alloy liquid is finally continuously risen, after reaching the top of the riser 92, the top contact 6 is connected, the control cabinet controls the exhaust valve 18 to be opened, the pressure is released by 1.5KPa, if the alloy liquid continuously rises in the fireproof layer 93, the gradient contacts 7L 1-L3 are sequentially communicated with the adjacent gradient contacts 7 at intervals of 25mm in height, the control cabinet respectively carries out automatic gradient pressure release according to the gradient value of 0.3KPa until the alloy liquid does not rise any more and hovers above the top contact 6;
And step 4, pressure maintaining and solidification: after the aluminum liquid hovers, the control cabinet controls the air inlet valve 17 to be intermittently opened and closed, the air pressure in the smelting furnace 1 is kept constant, the up-down floating error is within +/-1 KPa, until the alloy is solidified in the cavity of the casting mold 9, after solidification is completed, the metal mold is opened, the ejector rod ejects the casting, after the transfer is completed by the clamping of the mechanical arm, the surface cleaning of the mold and the contact is completed, the metal mold is combined with a film, and the next round of casting is performed.
Claims (8)
1. Open anti-gravity fills type solidification equipment, its characterized in that:
The device comprises a smelting furnace (1), a crucible (2), a furnace cover (3), a liquid lifting pipe (4), a charging stop contact (5), a top contact (6), a gradient contact (7), a forced pressure release contact (8) and an open casting mold (9); wherein: crucible (2) is placed in smelting furnace (1), furnace body installation admission valve (17) and discharge valve (18), bell (3) are installed in smelting furnace (1) top, and stalk (4) are installed on bell (3), and open casting mould (9) are wholly placed in stalk (4) and bell (3) top.
2. An open countergravity-fed coagulation device as defined in claim 1, wherein:
The furnace cover (3) and the flange of the smelting furnace (1) are provided with a sealing groove (11), graphite packing or asbestos packing can be placed in the sealing groove (11) to be sealed, a plurality of lift tube installation platforms (12) are designed on the furnace cover (3), when the lift tube (4) is not placed, the sealing is carried out by adopting a steel circular plate (13) with the same area, and a trapezoid steel choke ring (14) is designed on the periphery of the lift tube (4) installation platform.
3. An open countergravity-fed coagulation device as defined in claim 1, wherein:
an asbestos pad (15) is arranged between the flange bottom surface of the lift tube (4) and the center of the furnace cover (3) and is connected and sealed by bolts;
For large-capacity casting, 1 to 10 liquid lifting pipes (4) are adopted to simultaneously cast at a plurality of straight pouring gates (91) points set below a casting mould (9).
4. An open countergravity-fed coagulation device as defined in claim 1, wherein:
The top of the casting mould (9) is not closed, the riser heads (92) are of an open design, fireproof layers (93) with the thickness of 100-500 mm are arranged at the top of all riser heads (92), a choke groove (95) is arranged at the bottom of the casting mould (9), the choke groove (95) is positioned in a matched mode with a choke ring (14) of the furnace cover (3) and used for preventing alloy liquid from flowing out of the bottom, an asbestos pad (15) is arranged between the vicinity of a sprue (91) of the casting mould (9) and the upper plane of a flange of the riser tube (4), and the casting mould is sealed by placing weight above the dead weight of the casting mould (9) or by pressing.
5. The open-type antigravity filling coagulation apparatus and method according to claims 1 to 4, characterized in that: the filling type stop contact (5), the top contact (6), the gradient contact (7) and the forced pressure relief contact (8) are all wrapped by boron nitride BN or aluminum oxide Al 2O3 high-strength heat-resistant insulating ceramic tubes;
The ceramic tube is flush with the wall of the casting mould (9), the central contact extends out of the section of the ceramic tube for 1-2 mm, the filling type stop contact (5) is arranged in the open casting mould (9), the type top contact (6) is arranged at the top of a riser (92) of the open casting mould (9), the gradient contact (7) and the forced pressure release contact (8) are arranged in the fireproof layer (93) in a gradient manner, and all electromagnetic valves and contacts of the whole device are connected with the equipment control cabinet.
6. The open-type antigravity solidification apparatus according to claims 1 to 4, characterized in that:
The filling type stop contact (5) is arranged at the position of 1/5-1/2 of the height of a riser (92) at the top of an open casting mold (9), the filling type stop contact (6) is arranged at the top of the riser (92), 3-10 gradient contacts (7) are arranged in a fireproof layer (93) above the riser (92), the gradient contacts are respectively numbered as L 1～Ln, the gradient arrangement is carried out at the same height at intervals, the interval height H=10-200 mm, and a forced pressure release contact (8) is arranged at the top of the fireproof layer (93).
7. An open-type antigravity-type solidification method using the open-type antigravity-type solidification apparatus according to claim 1, characterized in that: the method comprises the following steps and contents in sequence:
(1) And (3) equipment installation: after the alloy smelting is completed, a furnace cover (3) is covered, and bolts are screwed for sealing; according to the position of a sprue (91) of the open casting mould (9), opening a steel circular plate (13) above a mounting platform of a corresponding lift tube (4), inserting the lift tube (4), and then screwing a flange bolt of the lift tube (4), so as to ensure the tightness between the flange bottom surface of the lift tube (4) and the mounting platform; placing a filter screen and an asbestos pad (15) on the upper plane of a flange of the lift tube (4), aligning the centers of a flow blocking groove (95) at the bottom of the open casting mold (9) and a flow blocking ring (14) of the furnace cover (3), placing the mold above the furnace cover (3) and the lift tube (4), and compacting the asbestos pad (15) to realize sealing; the charging type stop contact (5), the top contact (6), the gradient contact (7) and the forced pressure release contact (8) are respectively connected with a control silicon wire;
(2) And (3) air inlet filling: the control cabinet controls the air inlet valve (17) to open, compressed air is introduced into the smelting furnace (1), alloy liquid is pushed to enter the cavity of the open casting mould (9) through the riser tube (4), after the alloy liquid reaches the root of the riser tube (92), the charging stop contact (5) is connected, and the control cabinet closes the air inlet valve (17) to stop air inlet;
(3) Decompression and filling: after the air inlet is stopped, the air pressure in the smelting furnace (1) pushes the alloy liquid to continuously rise, the alloy liquid is finally enabled to continuously rise, after reaching the top of the riser (92), the top contact (6) is connected, and the control cabinet controls the exhaust valve (18) to be opened; the pressure relief is completed for one time according to the set value P 0; if the alloy liquid continuously rises into the fireproof layer (93), the gradient contacts (7) 1-n are sequentially communicated, the control cabinet performs gradient pressure relief according to a set gradient value P 1, namely, when the gradient contact (7) n is connected, the automatic pressure relief value is n multiplied by P 1 until the alloy liquid does not rise any more and hovers above the top contact (6);
(4) Pressure maintaining and solidifying: after the aluminum liquid hovers, the control cabinet controls the intermittent opening and closing of the air inlet valve (17), the air pressure in the smelting furnace (1) is kept constant, and the floating error is within +/-1 KPa up and down until the alloy solidifies in the cavity of the casting mould (9).
8. The open-type antigravity mold-filling coagulation method according to claim 7, wherein: the relation between the interval height H of the gradient contact (7) and the alloy liquid density rho, the gravity acceleration g and the gradient pressure relief value P 1 is P 1 = (0.5-1) rhogH.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311794481.3A CN117920976A (en) | 2023-12-25 | 2023-12-25 | Open type anti-gravity filling solidification device and filling solidification method using same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202311794481.3A CN117920976A (en) | 2023-12-25 | 2023-12-25 | Open type anti-gravity filling solidification device and filling solidification method using same |
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| Publication Number | Publication Date |
|---|---|
| CN117920976A true CN117920976A (en) | 2024-04-26 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311794481.3A Pending CN117920976A (en) | 2023-12-25 | 2023-12-25 | Open type anti-gravity filling solidification device and filling solidification method using same |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN117920976A (en) |
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2023
- 2023-12-25 CN CN202311794481.3A patent/CN117920976A/en active Pending
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