JP2006175510A - Method and device for molding water-soluble core - Google Patents
Method and device for molding water-soluble core Download PDFInfo
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- 238000000465 moulding Methods 0.000 title claims abstract description 53
- 238000000034 method Methods 0.000 title claims abstract description 43
- 239000002002 slurry Substances 0.000 claims abstract description 69
- 238000005266 casting Methods 0.000 claims abstract description 33
- 239000003232 water-soluble binding agent Substances 0.000 claims abstract description 33
- 238000011049 filling Methods 0.000 claims abstract description 27
- 238000002156 mixing Methods 0.000 claims abstract description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical group O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 141
- 239000004576 sand Substances 0.000 claims description 94
- 239000011230 binding agent Substances 0.000 claims description 56
- 229910017053 inorganic salt Inorganic materials 0.000 claims description 21
- 238000001035 drying Methods 0.000 claims description 20
- 230000007246 mechanism Effects 0.000 claims description 20
- 239000003110 molding sand Substances 0.000 claims description 18
- 239000002245 particle Substances 0.000 claims description 13
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 13
- 239000011734 sodium Substances 0.000 claims description 9
- 238000007664 blowing Methods 0.000 claims description 7
- 238000010438 heat treatment Methods 0.000 claims description 7
- CSNNHWWHGAXBCP-UHFFFAOYSA-L Magnesium sulfate Chemical compound [Mg+2].[O-][S+2]([O-])([O-])[O-] CSNNHWWHGAXBCP-UHFFFAOYSA-L 0.000 claims description 6
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 claims description 6
- 239000000843 powder Substances 0.000 claims description 6
- 239000000377 silicon dioxide Substances 0.000 claims description 5
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 claims description 4
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 4
- NJLLQSBAHIKGKF-UHFFFAOYSA-N dipotassium dioxido(oxo)titanium Chemical compound [K+].[K+].[O-][Ti]([O-])=O NJLLQSBAHIKGKF-UHFFFAOYSA-N 0.000 claims description 4
- 239000011256 inorganic filler Substances 0.000 claims description 4
- 229910003475 inorganic filler Inorganic materials 0.000 claims description 4
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 3
- 150000001450 anions Chemical class 0.000 claims description 3
- 150000001768 cations Chemical class 0.000 claims description 3
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052943 magnesium sulfate Inorganic materials 0.000 claims description 3
- 235000019341 magnesium sulphate Nutrition 0.000 claims description 3
- 150000003839 salts Chemical class 0.000 claims description 3
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 3
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 3
- 229910000029 sodium carbonate Inorganic materials 0.000 claims description 3
- 238000013022 venting Methods 0.000 claims description 3
- 229910052845 zircon Inorganic materials 0.000 claims description 3
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 3
- 239000005995 Aluminium silicate Substances 0.000 claims description 2
- BHPQYMZQTOCNFJ-UHFFFAOYSA-N Calcium cation Chemical compound [Ca+2] BHPQYMZQTOCNFJ-UHFFFAOYSA-N 0.000 claims description 2
- JLVVSXFLKOJNIY-UHFFFAOYSA-N Magnesium ion Chemical compound [Mg+2] JLVVSXFLKOJNIY-UHFFFAOYSA-N 0.000 claims description 2
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims description 2
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 claims description 2
- FKNQFGJONOIPTF-UHFFFAOYSA-N Sodium cation Chemical compound [Na+] FKNQFGJONOIPTF-UHFFFAOYSA-N 0.000 claims description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 2
- 235000012211 aluminium silicate Nutrition 0.000 claims description 2
- 229910021538 borax Inorganic materials 0.000 claims description 2
- 239000011575 calcium Substances 0.000 claims description 2
- 229910001424 calcium ion Inorganic materials 0.000 claims description 2
- 239000000945 filler Substances 0.000 claims description 2
- 239000011777 magnesium Substances 0.000 claims description 2
- 229910001425 magnesium ion Inorganic materials 0.000 claims description 2
- 239000000395 magnesium oxide Substances 0.000 claims description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 2
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 2
- 238000003825 pressing Methods 0.000 claims description 2
- 229910001415 sodium ion Inorganic materials 0.000 claims description 2
- 229910052938 sodium sulfate Inorganic materials 0.000 claims description 2
- 235000011152 sodium sulphate Nutrition 0.000 claims description 2
- 235000010339 sodium tetraborate Nutrition 0.000 claims description 2
- 239000000454 talc Substances 0.000 claims description 2
- 229910052623 talc Inorganic materials 0.000 claims description 2
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 claims description 2
- BSVBQGMMJUBVOD-UHFFFAOYSA-N trisodium borate Chemical compound [Na+].[Na+].[Na+].[O-]B([O-])[O-] BSVBQGMMJUBVOD-UHFFFAOYSA-N 0.000 claims description 2
- 239000011787 zinc oxide Substances 0.000 claims description 2
- 229910010272 inorganic material Inorganic materials 0.000 claims 1
- 239000011147 inorganic material Substances 0.000 claims 1
- 230000008569 process Effects 0.000 description 10
- 239000007788 liquid Substances 0.000 description 7
- 229910000838 Al alloy Inorganic materials 0.000 description 5
- 239000007864 aqueous solution Substances 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 230000006837 decompression Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 230000007613 environmental effect Effects 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- 238000003780 insertion Methods 0.000 description 3
- 230000037431 insertion Effects 0.000 description 3
- 238000005495 investment casting Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 230000035699 permeability Effects 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 239000011246 composite particle Substances 0.000 description 2
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 2
- 239000010954 inorganic particle Substances 0.000 description 2
- 229910052863 mullite Inorganic materials 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
- 238000004064 recycling Methods 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000000502 dialysis Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 238000005429 filling process Methods 0.000 description 1
- 239000007849 furan resin Substances 0.000 description 1
- 239000002440 industrial waste Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000003014 ion exchange membrane Substances 0.000 description 1
- -1 kaolinite Chemical compound 0.000 description 1
- 229910052622 kaolinite Inorganic materials 0.000 description 1
- 238000004898 kneading Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910003465 moissanite Inorganic materials 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 239000011295 pitch Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000008929 regeneration Effects 0.000 description 1
- 238000011069 regeneration method Methods 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
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- Casting Devices For Molds (AREA)
Abstract
Description
本発明は、流動性と充填性を低下させずに、強度を向上させた水溶性中子バインダを用いた水溶性中子の造型方法に関する。又、水溶性中子を用いたアルミ合金の鋳造方法に関する。更に、本発明は、水溶性中子の造型装置に関する。 The present invention relates to a method for molding a water-soluble core using a water-soluble core binder having improved strength without reducing fluidity and filling properties. The present invention also relates to an aluminum alloy casting method using a water-soluble core. Furthermore, the present invention relates to a water-soluble core molding apparatus.
鋳型に溶湯を圧入し，急冷凝固させて鋳物を製造することができる。このような、精密鋳造技術においては、機械部品等の精密鋳造品の内部に空間を設けるために、中子が広く利用されている。例えば、アルミ合金を使ったシリンダの内部空間、エグゾースト内部の冷却媒体通路の作製に中子は不可欠なものである。 The casting can be manufactured by pressing the molten metal into the mold and rapidly solidifying it. In such precision casting technology, a core is widely used to provide a space inside a precision casting product such as a machine part. For example, the core is indispensable for the production of the internal space of the cylinder using aluminum alloy and the cooling medium passage inside the exhaust.
中子の強度を増加させるためには、樹脂、無機塩等のバインダが使用されている。特に、中子バインダとして無機塩を用いることにより、鋳造時のガス発生量を低減させ、鋳造後は中子砂落しを水で行うことのできる水溶性中子が考えられている。しかしながら、実用化・量産化されたものはない。その理由は、バインダの結合力がないため、必要な中子強度を得ることが困難なことによる。 In order to increase the strength of the core, a binder such as a resin or an inorganic salt is used. In particular, by using an inorganic salt as a core binder, a water-soluble core that can reduce the amount of gas generated during casting and can perform core sand removal with water after casting is considered. However, none has been put into practical use or mass production. The reason is that it is difficult to obtain the necessary core strength because there is no binding force of the binder.
即ち、中子用鋳物砂に無機塩等のバインダを添加する場合、
１）バインダ量を増加すれば、中子強度が向上する。
２）バインダは、水に溶かして（飽和濃度にして）鋳物砂に添加する。よって、バインダ量の増加は、水の量の増加となる。
３）水の増加は、鋳物砂の流動性低下となり、中子型への鋳物砂の充填性を阻害する。
That is, when adding a binder such as an inorganic salt to the core foundry sand,
1) If the amount of the binder is increased, the core strength is improved.
2) The binder is dissolved in water (saturated concentration) and added to the foundry sand. Therefore, an increase in the amount of binder results in an increase in the amount of water.
3) The increase in water results in a decrease in the fluidity of the foundry sand and hinders the filling property of the foundry sand into the core mold.
このように、鋳物砂に、バインダだけの添加だと、中子強度と鋳物砂の流動性を両立させることができない。そこで、バインダ量を増加させずに、中子強度を向上させる技術が必要となっている。 Thus, if only the binder is added to the foundry sand, the core strength and the fluidity of the foundry sand cannot be made compatible. Therefore, a technique for improving the core strength without increasing the binder amount is required.
下記特許文献１には、流動性、充填性、成形性の改善を目的として、無機粒子に黒鉛をバインダで被覆してなる無機複合粒子であって、黒鉛の被覆量が無機粒子１００重量部に対して０．１〜５０重量部であり、かつ黒鉛に対するバインダの重量比が０．００２〜２である無機複合粒子からなる鋳物用砂の発明が開示されている。しかし、用いられているバインダは、フェノール樹脂、フラン樹脂、ピッチであり、本発明のように、水溶性中子を得るものではない。 The following Patent Document 1 discloses inorganic composite particles obtained by coating inorganic particles with graphite for the purpose of improving fluidity, filling properties, and moldability, and the coating amount of graphite is 100 parts by weight of inorganic particles. On the other hand, there is disclosed an invention of a sand for casting made of inorganic composite particles having a weight ratio of 0.1 to 50 parts by weight and a binder to graphite of 0.002 to 2. However, the binder used is phenol resin, furan resin, or pitch, and does not obtain a water-soluble core as in the present invention.
ところで、従来水溶性無機中子砂による造型はあまり報告されていない。これは、水溶性バインダを混練した鋳物砂を型内にブローイングする際、非常に流動性が悪いため、十分に鋳物砂を充填した中子が造型できないことによるものである。従来技術で水溶性バインダを用いて砂中子を造型した場合の問題点としては、
１．ウエットサンド状態の砂を吹き込むため、流動性が悪く複雑形状の充填は難しい
２．ブローイング前の砂ホッパー等は自然乾燥を防ぐ密閉等の構造が必要で設備が複雑になる
３．ブローイング後ブローヘッド内残砂が次第に乾燥するので、砂量制御が重要で複雑になる
４．これら湿砂がふれる設備内で次第に砂が乾燥付着するので、清掃が必要
が挙げられる。
By the way, there has not been much report on molding with a water-soluble inorganic core sand. This is because, when the foundry sand kneaded with the water-soluble binder is blown into the mold, the fluidity is very poor, so that the core sufficiently filled with the foundry sand cannot be formed. As a problem when molding sand cores using a water-soluble binder in the prior art,
1. Since wet sand is blown in, it is difficult to fill complex shapes due to poor fluidity. 2. Sand hoppers before blowing require a structure such as sealing to prevent natural drying, which complicates the equipment. Since the sand remaining in the blow head gradually dries after blowing, control of the amount of sand is important and complicated. Since the sand gradually dries and adheres in the facilities where the wet sand touches, cleaning is necessary.
そこで、下記非特許文献１には、鋳型チャンバー内に乾燥砂を充填し、充填後に前記鋳型内を減圧して液状バインダを注入させ、しかる後に前記鋳型内に乾燥空気やガスを吹き込み、加熱して鋳型を造型する鋳型造型法が開示されている。 Therefore, in Non-Patent Document 1 below, the mold chamber is filled with dry sand, and after filling, the mold is decompressed to inject a liquid binder, and then dry air or gas is blown into the mold and heated. A mold making method for making a mold is disclosed.
しかし、下記非特許文献１に記載の鋳型造型法では、上記造型法では鋳型内に乾燥砂を充填させているため、後工程において液状無機バインダを注入しても浸透性が悪く、温間強度（取り出し強度）が低く実用上問題が残る。 However, in the mold making method described in Non-Patent Document 1 below, dry sand is filled in the mold in the above molding method. Therefore, even if a liquid inorganic binder is injected in the subsequent process, the permeability is poor, and the warm strength. The (extraction strength) is low and problems remain in practice.
又、乾燥砂（新砂）充填型内にバインダ液を注入しても、温間強度（取り出し強度）が通常混練砂の１／２ほどしかなく、実用上問題であった。新砂に液体バインダを注入した場合の低強度の理由は、ブロー後の砂粒問をバインダが通過するだけで混練（コーティング）工程がないので、砂粒接触部の微小空間に注入バインダが入りにくいことによる。一般にも、良く混練した方がバインダが均一にコーティングされ強度がでることと同様の理由による。 Moreover, even when the binder liquid was poured into the dry sand (new sand) filling mold, the warm strength (removal strength) was only about 1/2 that of the normally kneaded sand, which was a practical problem. The reason for the low strength when liquid binder is injected into fresh sand is that the binder passes only through the sand particles after blow and there is no kneading (coating) step, so the injection binder is difficult to enter into the minute space of the sand particle contact part. . Generally, it is because of the same reason that the binder is uniformly coated and the strength is better when kneaded well.
上記問題に鑑み、本発明は、流動性、充填性に優れ、強度を向上させた水溶性中子の造型方法を提供し、水溶性中子を実用性のあるものとすることを目的とする。 In view of the above problems, an object of the present invention is to provide a method for forming a water-soluble core having excellent fluidity and filling properties and improved strength, and to make the water-soluble core practical. .
本発明者らは、鋳物砂を従来の乾燥砂に代えて水溶性無機バインダのスラリーとすることで上記課題が解決されることを見出し、本発明に到達した。 The present inventors have found that the above-mentioned problems can be solved by replacing the foundry sand with a conventional dry sand to form a water-soluble inorganic binder slurry, and have reached the present invention.
即ち、第１に、本発明は、鋳物砂中子の造型方法の発明であり、鋳物砂に水溶性バインダを混合してスラリー状とし、該スラリーを鋳型内に充填し、その後該充填物を乾燥させて成型する鋳物砂中子の造型方法において、該スラリーを鋳型内に充填する際に、（ａ）鋳型のキャビティー内を減圧にする及び／又は（ｂ）該スラリーを加圧して鋳型内に充填する。鋳物砂と水溶性バインダを混合してスラリー状にして、これを鋳型内に充填させるため、鋳物型へのスラリーの浸透性が向上し、温間強度を上げることができる。 That is, first, the present invention is an invention of a molding sand core molding method, in which a water-soluble binder is mixed with casting sand to form a slurry, and the slurry is filled into a mold, and then the filling is used. In a molding sand core molding method for drying and molding, when the slurry is filled in a mold, (a) the mold cavity is depressurized and / or (b) the slurry is pressurized to form a mold. Fill inside. Since the foundry sand and the water-soluble binder are mixed to form a slurry and filled in the mold, the permeability of the slurry into the casting mold is improved and the warm strength can be increased.
本発明において、前記鋳物砂に水溶性バインダを混合したスラリーの粘度としては、４〜１２ｃｐが好ましい。 In the present invention, the viscosity of the slurry obtained by mixing the foundry sand with a water-soluble binder is preferably 4 to 12 cp.
水溶性バインダとしては水溶性無機塩バインダや有機バインダを用い得ることができるが、加熱時に焦げ付きがないことから水溶性無機塩バインダが好ましい。 As the water-soluble binder, a water-soluble inorganic salt binder or an organic binder can be used, but a water-soluble inorganic salt binder is preferable because it does not burn when heated.
混練される鋳物砂及び水溶性バインダの量の目安としては、鋳物砂と水溶性バインダの重量比が１：０．１〜１：５であることが好ましく、１：０．５〜１：１であることがより好ましい。 As a measure of the amount of foundry sand and water-soluble binder to be kneaded, the weight ratio of foundry sand and water-soluble binder is preferably 1: 0.1 to 1: 5, and 1: 0.5 to 1: 1. It is more preferable that
本発明では、前記鋳物砂を乾燥させて成型する工程は、（１）鋳型内への乾燥用熱風の吹き込み、（２）鋳型の加熱、（３）マイクロウェーブでの鋳物砂の加熱の１種又はこれらの併用によって行うことができる。この中で、鋳型内への乾燥用熱風の吹き込みが好ましい。 In the present invention, the step of drying and molding the foundry sand includes (1) blowing hot air for drying into the mold, (2) heating the mold, and (3) heating the foundry sand in the microwave. Or it can carry out by these combined use. Among these, it is preferable to blow hot air for drying into the mold.
本発明の鋳物砂中子の造型方法に用いられる水溶性バインダとしては無機、有機であり、特に限定されないが、マグネシウムイオン（Ｍｇ２＋）、ナトリウムイオン（Ｎａ＋）、カルシウムイオン（Ｃａ２＋）から選択されるカチオンと、ＳＯ４ ２−、ＣＯ３ ２−、ＨＣＯ３ ２−、Ｂ４Ｏ７ −から選択されるアニオンとの組み合わせからなる水溶性無機塩の１種以上から成る水溶性中子バインダが好ましく例示される。これら特定のカチオンとアニオンの組み合わせからなる無機塩は、バインダとしての強度、可溶性、充填性等を満たす。より具体的には、硫酸マグネシウム（ＭｇＳＯ４）、炭酸ナトリウム（Ｎａ２ＣＯ３）、４ホウ酸ナトリウム（Ｎａ２Ｂ４Ｏ７）、硫酸ナトリウム（Ｎａ２ＳＯ４）から選択される１種以上が挙げられる。 The water-soluble binder used in the casting sand core molding method of the present invention is inorganic or organic, and is not particularly limited. From the magnesium ion (Mg 2+ ), sodium ion (Na + ), and calcium ion (Ca 2+ ). A water-soluble core comprising at least one water-soluble inorganic salt comprising a combination of a selected cation and an anion selected from SO 4 2− , CO 3 2− , HCO 3 2− , and B 4 O 7 − A binder is preferably exemplified. The inorganic salt composed of a combination of these specific cations and anions satisfies the strength, solubility, filling properties and the like as a binder. More specifically, at least one selected from magnesium sulfate (MgSO 4 ), sodium carbonate (Na 2 CO 3 ), sodium borate (Na 2 B 4 O 7 ), and sodium sulfate (Na 2 SO 4 ). Is mentioned.
本発明では、水溶性無機塩バインダに、珪砂（珪粉）、アルミナ、チタン酸カリウム、炭化珪素、珪酸ジルコン、繊維状チタン酸カリウム、酸化チタン、酸化亜鉛、酸化鉄、酸化マグネシウムから選択される無機フィラーの１種以上が添加することができる。無機フィラーを添加することで水溶性中子の高温強度が更に向上し、造型された中子のハンドリングに優れるという実用性が生じる。 In the present invention, the water-soluble inorganic salt binder is selected from silica sand (silica powder), alumina, potassium titanate, silicon carbide, zircon silicate, fibrous potassium titanate, titanium oxide, zinc oxide, iron oxide and magnesium oxide. One or more inorganic fillers can be added. By adding an inorganic filler, the high-temperature strength of the water-soluble core is further improved, resulting in the practicality of being excellent in handling of the molded core.
本発明で用いられる特定の無機フィラーは、表面が無機塩バインダで被覆された鋳物砂粒子の接点付近に存在して、鋳物砂粒子の結合力を高めるものである。その平均粒径は、数μｍ〜数１０μｍ程度が鋳物砂の接点付近に存在するのに好ましい。 The specific inorganic filler used in the present invention is present near the contact point of the foundry sand particles whose surface is coated with the inorganic salt binder, and enhances the binding force of the foundry sand particles. The average particle size is preferably about several μm to several tens of μm in the vicinity of the contact point of the foundry sand.
更に、本発明では、表面が水溶性無機塩バインダで被覆された鋳物用砂の隙間を無機微粉末が充填されていることが好ましい。ここで、無機微粉末は、表面が無機塩バインダで被覆された鋳物砂粒子の隙間に充填されて、鋳物砂粒子の結合力を高めるものである。具体的には、カオリナイト、デッカイト、ハロサイト等のカオリン、タルクから選択される１種以上が好ましく例示される。その平均粒径は、数μｍ〜数１０μｍ程度が鋳物砂の隙間に充填するのに好ましい。 Further, in the present invention, it is preferable that the inorganic fine powder is filled in the gaps in the sand for casting whose surface is coated with a water-soluble inorganic salt binder. Here, the inorganic fine powder is filled in the gaps between the foundry sand particles whose surfaces are coated with the inorganic salt binder to increase the binding force of the foundry sand particles. Specifically, one or more selected from kaolin and talc such as kaolinite, decaite, and halosite are preferably exemplified. The average particle size is preferably about several μm to several tens of μm for filling the gaps in the foundry sand.
本発明で用いられる鋳物砂粒子は、従来知られたものを用いることができる。具体的には、ＳｉＣ，アルミナ，ムライト，シリカ，ジルコンを用いることが好ましい。これらは，優れた強度，低熱膨張率を有するとともに入手が比較的容易であり、強度，寸法精度等に優れた水溶性中子を製造することができる。 As the foundry sand particles used in the present invention, those conventionally known can be used. Specifically, it is preferable to use SiC, alumina, mullite, silica, or zircon. These have excellent strength and low thermal expansion coefficient and are relatively easily available, and can produce water-soluble cores excellent in strength, dimensional accuracy, and the like.
本発明で造型される水溶性中子は、鋳物砂粒子の表面が水溶性無機塩バインダで被覆された水溶性中子であり、十分な中子強度と流動性（充填性）を兼ね備えている。 The water-soluble core formed by the present invention is a water-soluble core in which the surface of the casting sand particles is coated with a water-soluble inorganic salt binder, and has sufficient core strength and fluidity (fillability). .
第２に、本発明は上記鋳物砂中子造型に用いられる鋳物砂中子造型装置の発明であり、鋳物砂に水溶性バインダを混合してスラリー状とし、該スラリーを鋳型内に充填し、その後該充填物を乾燥させて成型する鋳物砂中子の造型方法に用いる造形装置であって、該スラリーの鋳型内への充填を行うための、（ｃ）鋳型のキャビティー内を負圧にする減圧機構及び／又は（ｄ）該スラリーを加圧して鋳型内に充填する加圧機構を備えている。 Second, the present invention is an invention of a molding sand core molding apparatus used for the molding sand core molding described above, wherein a water-soluble binder is mixed with the molding sand to form a slurry, and the slurry is filled in a mold, A molding apparatus for use in a molding sand core molding method for drying and then molding the filler, and (c) for filling the slurry into the mold with a negative pressure inside the mold cavity And / or (d) a pressurizing mechanism for pressurizing and filling the slurry into the mold.
本発明の鋳物砂中子造型装置では、前記鋳型がキャビティー内のエア抜き及び／又は乾燥時の熱風抜きのための排気ベントを１個以上備えていることが好ましい。 In the foundry sand core molding apparatus of the present invention, it is preferable that the mold is provided with one or more exhaust vents for venting air in the cavity and / or venting hot air during drying.
また、本発明の鋳物砂中子の造型装置では、前記（ｄ）スラリーを加圧して鋳型内に充填する加圧機構が、充填物を乾燥させて成型する際に、（ｅ）熱風送風機構に置換可能とすることができる。 In the molding sand core molding apparatus of the present invention, when the pressurizing mechanism for pressurizing (d) the slurry and filling the mold into the mold, (e) the hot air blowing mechanism when the filling is dried and molded. Can be substituted.
本発明の鋳物砂中子の造型装置では、スラリーに対する加圧及び／又は減圧を効率よく行うために、以下に示すように幾つかの配置が考えられる。
１．前記（ｄ）スラリーを加圧して鋳型内に充填する加圧機構を、スラリーを鋳型本体へ落とし込む方式とする。
２．前記（ｄ）スラリーを加圧して鋳型内に充填する加圧機構を、スラリーを鋳型本体へ押し上げる方式とする。
３．前記（ｃ）鋳型のキャビティ内の減圧機構を、スラリーを鋳型本体へ吸い上げる方式とする。
４．前記（ｃ）鋳型のキャビティ内の減圧機構を、スラリーを鋳型本体から吸い落とす方式とする。
In the molding sand core molding apparatus of the present invention, in order to efficiently perform pressurization and / or decompression on the slurry, several arrangements are possible as shown below.
1. The (d) pressurizing mechanism for pressurizing and filling the slurry into the mold is a system for dropping the slurry into the mold body.
2. The (d) pressurizing mechanism that pressurizes the slurry and fills it into the mold is a system that pushes up the slurry to the mold body.
3. (C) The pressure reducing mechanism in the mold cavity is configured to suck up the slurry into the mold body.
4). (C) The pressure reducing mechanism in the mold cavity is configured to suck the slurry from the mold body.
第３に、本発明は、上記の鋳物砂中子の造型方法によって造型された水溶性中子を用いたアルミ合金の鋳造方法である。水溶性中子を用いているため、鋳造後の砂落としが容易である。本発明により、例えば、アルミ合金シリンダ等の精密鋳造品を製造することが出来る。 Thirdly, the present invention is an aluminum alloy casting method using a water-soluble core formed by the above casting sand core molding method. Since a water-soluble core is used, sand removal after casting is easy. According to the present invention, for example, a precision casting such as an aluminum alloy cylinder can be manufactured.
なお、本発明では、水溶性中子バインダを砂落とし後に回収してリユースすることで、環境問題に対処することができる。鋳物砂と水溶性バインダのスラリー状の混合物を用いて、該スラリーを鋳型内に充填し、該スラリーを乾燥させて成型して鋳物砂中子を造型した後、鋳造工程、砂落とし工程を経た後、該水溶性バインダを水溶液として回収し、得られた水溶液から水分を蒸発等で分離させて、水溶性バインダを回収する。回収された水溶性バインダは上記の鋳物砂中子の造型方法に再利用される。水溶性無機塩バインダを繰り返し再利用することにより、環境負荷の少ない鋳物砂中子の造型方法となる。水溶性無機塩バインダを水溶液として回収した後、イオン交換膜を用いた透析により該水溶性無機塩を濃縮することも可能である好ましい。 In the present invention, an environmental problem can be dealt with by recovering and reusing the water-soluble core binder after sand removal. Using a slurry-like mixture of foundry sand and water-soluble binder, the slurry was filled into a mold, the slurry was dried and molded to form a foundry sand core, followed by a casting process and a sand removal process. Thereafter, the water-soluble binder is recovered as an aqueous solution, and water is separated from the obtained aqueous solution by evaporation or the like to recover the water-soluble binder. The recovered water-soluble binder is reused in the above molding sand core molding method. By repeatedly reusing the water-soluble inorganic salt binder, it becomes a molding sand core molding method with less environmental load. It is preferable that after the water-soluble inorganic salt binder is recovered as an aqueous solution, the water-soluble inorganic salt can be concentrated by dialysis using an ion exchange membrane.
水溶性中子バインダの回収・再利用（リユース）方法により、従来大量の産業廃棄物として、水溶性中子バインダを含む廃液の処置が困難であったものが、ほぼ全量回収することが可能となり、再度水溶性中子バインダとして利用できることとなった。これにより、環境問題が解決されたのみならず、アルミ合金シリンダ等の製造コストを大幅に削減することが出来る。 By collecting and reusing (reusing) water-soluble core binders, it has become possible to recover almost all of the waste that has been difficult to treat with water-soluble core binders as a large amount of industrial waste. It can be used again as a water-soluble core binder. This not only solves environmental problems, but can also significantly reduce the manufacturing cost of aluminum alloy cylinders and the like.
本発明によれば、鋳物砂と水溶性バインダのスラリー状の混合物を用いて、該スラリーを鋳型内に充填し、該スラリーを乾燥させて成型して鋳物砂中子を造型するため、鋳型への鋳物砂と水溶性バインダのスラリーの浸透性が向上し、鋳物砂中子の温間強度を上げることができる。特に、水溶性無機塩から成る水溶性中子バインダを用いることで、十分な中子強度と水溶性を併せ持つ水溶性中子を得ることができる。また、この水溶性中子を用いることで、鋳造時に型崩れせず、鋳造後の除去が容易な鋳造を行うことができる。 According to the present invention, a slurry-like mixture of foundry sand and a water-soluble binder is used to fill the slurry into a mold, and the slurry is dried and molded to form a foundry sand core. The permeability of the slurry of the foundry sand and the water-soluble binder is improved, and the warm strength of the foundry sand core can be increased. In particular, by using a water-soluble core binder made of a water-soluble inorganic salt, a water-soluble core having both sufficient core strength and water solubility can be obtained. Further, by using this water-soluble core, it is possible to perform casting that does not lose its shape during casting and can be easily removed after casting.
即ち、本発明の効果を列挙すれば以下のようになる。
１．無機バインダを用いても複雑な形状の鋳型も砂充填でき、鋳型、中子の造型が可能となる。
２．スラリー状の砂の準備は所定の濃度のバインダをスラリー状になるように砂に加えるだけでよく、乾燥の心配も少なく取り扱いが簡単である。（余分なバインダはエアとともに排出されるのでコントロール不要）
３．中子のバインダ量は液濃度、吸引圧／加圧条件でコントロールできるため、造型後の中子強度は広範囲に調整可能となる（高強度中子の作製が可能）。また過剰に注入しても粒子間隙間の残存量は一定にできるため、液量のコントロールはラフでも問題ない。
４．減圧により水の沸点が下がり、より低温で水が蒸発・硬化するので金型温度を低下できる。
５．中子内の温度差により、塩濃度の分布は金型面（中子では外側）が密となる。鋳物砂粒子間隙が塩で満たされることにより中子表面が平滑になり、鋳物表面粗度が向上する。
６．スラリーの乾燥・硬化は加熱金型の熱伝導により促進されるため中子に温度差が生じる。この現象を利用して内部が硬化するまえにスラリーを排出することにより中空中子の作製が可能となる。
７．鋳物を水に浸すことにより硬化バインダが溶解し中子が崩壊するから、砂分離（砂落とし）が可能である。この際バインダ溶液そのものを用いれば、取り出された鋳物砂は造型前に近い組成のスラリーとなる。本発明によれば少しの水を加えてバインダ濃度を調整するだけでそのままスラリー状鋳物砂とて扱えるので、いわゆる砂再生工程が不用となる。即ち、新砂相当にする必要もなく又焙焼や研磨等のあらゆる再生工程を省略できる。
８．所定比で混合された鋳物砂と水溶性バインダのスラリーをブローイングするので、スラリーの取り扱い、計量が容易で乾燥の心配も少なく、取り扱いが容易である。
９．鋳物砂を工程内で再使用する場合、砂にバインダが付着しているが、本発明によればそのまま事前混練砂として扱えるので、いわゆる砂再生工程が不用となる。新砂相当にするための、焙焼や研磨等も不用である。
That is, the effects of the present invention are enumerated as follows.
1. Even if an inorganic binder is used, a mold having a complicated shape can be filled with sand, and a mold and a core can be formed.
2. The slurry-like sand is prepared simply by adding a binder having a predetermined concentration to the sand so as to form a slurry, and is easy to handle with little fear of drying. (Excess binder is discharged together with air, so no control is required)
3. Since the amount of the binder in the core can be controlled by the liquid concentration and suction pressure / pressurization conditions, the core strength after molding can be adjusted in a wide range (high strength core can be produced). In addition, even if it is excessively injected, the residual amount between the gaps between the particles can be made constant, so there is no problem even if the liquid amount is controlled roughly.
4). The boiling point of water is lowered by the reduced pressure, and the mold temperature can be lowered because water evaporates and hardens at a lower temperature.
5. Due to the temperature difference in the core, the distribution of salt concentration becomes dense on the mold surface (outside of the core). When the gap between the casting sand particles is filled with the salt, the core surface becomes smooth and the casting surface roughness is improved.
6). Since the drying and curing of the slurry is accelerated by the heat conduction of the heating mold, a temperature difference occurs in the core. By utilizing this phenomenon and discharging the slurry before the inside is cured, a hollow core can be produced.
7). By immersing the casting in water, the hardened binder dissolves and the core collapses, so that sand separation (sand removal) is possible. At this time, if the binder solution itself is used, the extracted foundry sand becomes a slurry having a composition close to that before molding. According to the present invention, the so-called sand recycling process is not necessary because it can be treated as slurry-like casting sand as it is by adjusting the binder concentration by adding a little water. That is, it is not necessary to make it equivalent to fresh sand, and all regeneration processes such as roasting and polishing can be omitted.
8). Since the slurry of the foundry sand and the water-soluble binder mixed at a predetermined ratio is blown, the handling and measurement of the slurry is easy, and there is little fear of drying, and the handling is easy.
9. When the foundry sand is reused in the process, the binder adheres to the sand, but according to the present invention, it can be handled as pre-kneaded sand as it is, so the so-called sand recycling process becomes unnecessary. There is no need for roasting or polishing to make it equivalent to fresh sand.
本発明によって、中子の温間強度を上げることができることの作用原理は必ずしも解明されないが、鋳物砂の表面の水溶性無機塩の結晶が、滑らかに、均一に被覆されることにより、結晶強度を発揮させ、造型された中子の温間強度を上げるものと推定される。 Although the principle of action that the warm strength of the core can be increased by the present invention is not necessarily elucidated, the crystal strength of the water-soluble inorganic salt on the surface of the casting sand is smoothly and uniformly coated. It is estimated that the warm strength of the molded core is increased.
図１に、本発明の鋳物砂中子の各造型工程を示す。図１（ａ）は、スラリー砂充填工程であり、鋳物砂と水溶性バインダの混合物からなるスラリー状鋳物砂１を、ノズル６を介して、スラリーボックス２に入れ、加圧エア３及び排気ベント８からの減圧吸引４よって、鋳物型５内のキャビティー７に充填される。
In FIG. 1, each molding process of the foundry sand core of this invention is shown. FIG. 1 (a) is a slurry sand filling step, in which a slurry-like foundry sand 1 made of a mixture of foundry sand and a water-soluble binder is put into a slurry box 2 through a nozzle 6, and
図１（ｂ）は、乾燥・成型工程であり、キャビティー７に充填されたスラリー状鋳物砂に熱風挿入ヘッド９より乾燥用熱風１０を吹き込み、該スラリー状鋳物砂を乾燥・造型させて成型中子１１とする。
FIG. 1 (b) shows a drying / molding process, in which hot air for drying 10 is blown from the hot air insertion head 9 into the slurry-like foundry sand filled in the
なお、図１において排気ベント８は１箇所設けられているが、所望により複数個設けても良い。また、排気ベント８の隙間を小さく、例えば０．１ｍｍ程度に、すると鋳物砂の詰まりが少なくなる。一方、該隙間が水溶性バインダによって目詰まりした時は、本発明の操作後に水洗することで容易に流すことができる。 In FIG. 1, one exhaust vent 8 is provided, but a plurality of exhaust vents 8 may be provided if desired. Further, when the clearance of the exhaust vent 8 is made small, for example, about 0.1 mm, clogging of foundry sand is reduced. On the other hand, when the gap is clogged with the water-soluble binder, it can be easily washed by washing with water after the operation of the present invention.
図２（ａ）〜（ｄ）に、本発明の鋳物砂中子造型に用いられる鋳物砂中子造型装置の幾つかの類型を示す。これらは、スラリーに対する加圧機構及び／又は減圧機構の組み合わせである。図２（ａ）は、スラリーを加圧して鋳型内に充填する加圧機構を、スラリーを鋳型本体へ落とし込む方式とする図であり、図２（ｂ）は、スラリーを加圧して鋳型内に充填する加圧機構を、スラリーを鋳型本体へ落とし込む方式とするとともに、鋳型のキャビティー内の減圧機構を、スラリーを鋳型本体へ吸い上げる方式とする図であり、図２（ｃ）は、鋳型のキャビティー内の減圧機構を、スラリーを鋳型本体から吸い落とす方式とする図であり、図２（ｄ）は、スラリーを加圧して鋳型内に充填する加圧機構を、スラリーを鋳型本体へ押し上げる方式とするとともに、鋳型のキャビティー内の減圧機構を、スラリーを鋳型本体から吸い落とす方式とする図である。 2 (a) to 2 (d) show several types of foundry sand core molding devices used in the foundry sand core molding of the present invention. These are a combination of a pressurizing mechanism and / or a depressurizing mechanism for the slurry. FIG. 2 (a) is a diagram in which a pressurizing mechanism for pressurizing the slurry and filling it into the mold is a system in which the slurry is dropped into the mold main body, and FIG. 2 (b) is a diagram in which the slurry is pressurized and placed in the mold. The pressurizing mechanism for filling is a system in which the slurry is dropped into the mold body, and the pressure reducing mechanism in the mold cavity is a system in which the slurry is sucked into the mold body, and FIG. FIG. 2 (d) is a diagram showing a system in which the pressure reducing mechanism in the cavity sucks the slurry from the mold body, and FIG. It is a figure which makes it a system and makes the pressure reduction mechanism in the cavity of a casting_mold | template the system which sucks down a slurry from a casting_mold | template main body.
これらの加圧機構及び／又は減圧機構の組み合わせの中で、加圧と減圧の両者を組み合わせた鋳物砂中子造型装置が好ましい。 Among these pressurization mechanisms and / or decompression mechanisms, a foundry sand core molding apparatus that combines both pressurization and decompression is preferable.
以下、図１に準じて、本発明の実施例を説明する。
鋳物砂として乾燥したムライト系人工砂を用い、水溶性無機塩バインダとして硫酸マグネシウム（ＭｇＳＯ４）１０ｇ（１０％）と炭酸ナトリウム（Ｎａ２ＣＯ３）１０ｇ（１０％）を水１００ｃｃ当たりに溶かした水溶液を用いた。これら鋳物砂と水溶性無機塩バインダ水溶液を１：０．５の割合で混合した。得られた無機水溶性バインダ溶液でスラリー状にした鋳物砂１をスラリーボックス２に入れた状態から、加圧エア３を吹込むと同時に減圧吸引４する。前記スラリーボックス２と鋳物型５は吹き込みスラリー中に開口部が達するようにしたパイプと結合しているノズル６を介して連通かつ密着しているので鋳物砂１は鋳物型内のキャビティー７に充填される。この際、鋳物砂は多量のバインダ溶液でスラリー状になっているので、液体に近い状態で隅々まで充填する。（以上、スラリー砂充填工程）
An embodiment of the present invention will be described below with reference to FIG.
Using dry mullite artificial sand as foundry sand, 10 g (10%) of magnesium sulfate (MgSO 4 ) and 10 g (10%) of sodium carbonate (Na 2 CO 3 ) were dissolved per 100 cc of water as a water-soluble inorganic salt binder. An aqueous solution was used. These foundry sands and a water-soluble inorganic salt binder aqueous solution were mixed at a ratio of 1: 0.5. From the state in which the foundry sand 1 made into a slurry form with the obtained inorganic water-soluble binder solution is put in the slurry box 2, the
次に、スラリーボックスに代え、熱風挿入ヘッド９をセットし、所定の熱風待ち保持時間待機後、下部から乾燥用熱風１０を入れ、鋳物型内で前記スラリー状態の鋳物砂を乾燥し成形する。乾燥を熱風で行う以外に型の加熱も有効であり、また型加熱の代わりにマイクロウェーブで鋳物砂を加熱する方法もある。最後に、成形完了後、型を開き、成形中子１１を取り出す。（以上、乾燥・成形工程）
Next, in place of the slurry box, the hot air insertion head 9 is set, and after waiting for a predetermined hot air waiting time, the
［性能比較］
本発明のスラリー状の鋳物砂を鋳物型に充填し、その後水分を乾燥する造型法（実施例）と、水分３％程度の湿砂をエアブローする造型法（比較例）で、φ３０×Ｈ１９５の丸棒の中子を作製した。比較例の中子の充填性を１００とした時の実施例の中子の充填性は１０１．６とやや向上した。また、比較例の中子の冷間強度を１００とした時の実施例の中子の冷間強度は１３８と大幅に向上した。更に、比較例の中子の温間強度を１００とした時の実施例の中子の温間強度は１３６と大幅に向上した。
[Performance comparison]
In the molding method of filling slurry casting sand of the present invention into a casting mold and then drying moisture (Example), and the molding method of air blowing wet sand having a moisture content of about 3% (Comparative Example), φ30 × H195 A round bar core was made. When the filling property of the core of the comparative example was set to 100, the filling property of the core of the example was slightly improved to 101.6. Further, when the cold strength of the core of the comparative example was set to 100, the cold strength of the core of the example was significantly improved to 138. Furthermore, when the warm strength of the core of the comparative example was set to 100, the warm strength of the core of the example was greatly improved to 136.
バインダ濃度が３４％の時の冷間強度を１００とすると、バインダ濃度が２８％の時の冷間強度は７０であり、バインダ濃度が２３％の時の冷間強度は４５であり、バインダ濃度が１７％の時の冷間強度は３５であり、バインダ濃度が５％の時の冷間強度は１５であった。これより、スラリーのバインダ濃度を調整することにより、冷間強度と温間強度を制御することが可能である。 Assuming that the cold strength when the binder concentration is 34% is 100, the cold strength when the binder concentration is 28% is 70, and the cold strength when the binder concentration is 23% is 45. When 17%, the cold strength was 35, and when the binder concentration was 5%, the cold strength was 15. Thus, it is possible to control the cold strength and the warm strength by adjusting the binder concentration of the slurry.
鋳物砂と水溶性バインダのスラリー状の混合物を用いることによって、該スラリーを鋳型内に充填し、該スラリーを乾燥させて成型して鋳物砂中子を造型することができる。これにより、水溶性中子バインダを用いて十分な中子強度と水溶性を併せ持つ水溶性中子を得ることができる。また、水溶性バインダ及び鋳物砂は繰り返し再利用できる。これにより、本発明は水溶性中子を用いた鋳造の普及に貢献する。 By using a slurry-like mixture of foundry sand and a water-soluble binder, the slurry can be filled in a mold, the slurry can be dried and molded to form a foundry sand core. Thereby, a water-soluble core having both sufficient core strength and water-solubility can be obtained using a water-soluble core binder. Also, the water-soluble binder and foundry sand can be reused repeatedly. Thus, the present invention contributes to the spread of casting using a water-soluble core.
１：スラリー状鋳物砂、２：スラリーボックス、３：加圧エア、４：減圧吸引、５：鋳物型、６：ノズル、７：キャビティー、８：排気ベント、９熱風挿入ヘッド、１０：乾燥用熱風、１１：成型中子。 1: Slurry foundry sand, 2: Slurry box, 3: Pressurized air, 4: Vacuum suction, 5: Casting mold, 6: Nozzle, 7: Cavity, 8: Exhaust vent, 9 Hot air insertion head, 10: Drying Hot air for use, 11: molding core.
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| KR20200120590A (en) * | 2018-11-16 | 2020-10-21 | 재단법인 한국탄소융합기술원 | Water-soluble core material and manufacturing method thereof |
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| CN114290708A (en) * | 2021-12-30 | 2022-04-08 | 中国科学院长春光学精密机械与物理研究所 | Integrated forming preparation process for large-size carbon fiber plate type workpiece |
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