JP4776953B2 - Casting manufacturing method - Google Patents
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Description
本発明は鋳物の製造方法、及び該製造方法に用いる鋳物砂に関する。 TECHNICAL FIELD The present invention relates to a casting production method and casting sand used in the production method.
近年、各種産業機器製造、特に自動車関連に使用される鋳物においては、低燃費や省資源化等の観点から、軽量化やコンパクト設計によって、薄肉でしかも複雑な形状を有する鋳物、所謂、薄肉鋳物が強く要求されている。 In recent years, in castings used in various industrial equipment manufacturing, especially in automobile-related industries, from the viewpoint of low fuel consumption and resource saving, castings with thin and complex shapes due to light weight and compact design, so-called thin castings Is strongly demanded.
薄肉鋳物を砂型で重力鋳造により鋳造製造するには、薄肉であるがゆえに、鋳型内への溶融金属の充填が困難であり、溶融金属の流動性によりその鋳物品質が大きく左右される。 In order to produce a thin casting by gravity casting with a sand mold, since it is thin, it is difficult to fill the mold with molten metal, and the casting quality is greatly affected by the fluidity of the molten metal.
溶融金属の流動性を向上させる為に、鋳型の加熱により溶融金属の温度低下量の低減および水分などのガス発生の原因物質を除去する方法（たとえば、特許文献１）が提案されている。
しかしながら、特許文献１の方法は、加熱時の熱により鋳型表面安定性が低下する為、鋳物の表面平滑性が悪化する課題がある。 However, the method of Patent Document 1 has a problem that the surface smoothness of the casting deteriorates because the mold surface stability is lowered by the heat during heating.
本発明は、表面平滑性に優れた薄肉鋳物の製造方法を提供することを課題とする。 This invention makes it a subject to provide the manufacturing method of the thin casting which was excellent in surface smoothness.
本発明は、火炎溶融法にて製造された球状鋳物砂より得られる鋳型を用いて、６ｍｍ以下の薄肉部分を有する鋳物（以下、薄肉鋳物ということもある）を製造する方法であって、表面温度が６０℃〜２５０℃の鋳型に溶融金属を注入する、鋳物の製造方法に関する。 The present invention is a method for producing a casting having a thin portion of 6 mm or less (hereinafter sometimes referred to as a thin casting) using a mold obtained from a spherical casting sand produced by a flame melting method. The present invention relates to a casting manufacturing method in which molten metal is injected into a mold having a temperature of 60 ° C to 250 ° C.
また、本発明は、上記本発明の製造方法に用いられる、火炎溶融法にて製造された球状鋳物砂に関する。 Moreover, this invention relates to the spherical foundry sand manufactured by the flame melting method used for the manufacturing method of the said invention.
本発明では、加熱時の熱による鋳型の表面安定性の劣化が少なく、表面平滑性の優れた薄肉鋳物を得ることができる。 In the present invention, there is little deterioration of the surface stability of the mold due to heat at the time of heating, and a thin casting having excellent surface smoothness can be obtained.
本発明は、薄肉鋳物の製造方法に関する。本発明の薄肉鋳物とは、成形された鋳物の最狭部分の厚みが６ｍｍ以下の薄肉部分を有する鋳物を表す。本発明の製造法は、より効果を発現する観点から、３ｍｍ以下、更に２ｍｍ以下、特に１ｍｍ以下の薄肉部分を有する鋳物に好適である。 The present invention relates to a method for producing a thin casting. The thin casting of the present invention refers to a casting having a thin portion where the thickness of the narrowest portion of the molded casting is 6 mm or less. The production method of the present invention is suitable for castings having a thin portion of 3 mm or less, further 2 mm or less, and particularly 1 mm or less, from the viewpoint of expressing the effect.
本発明において、鋳型の表面温度を加熱する方法としては、特に限定されないが、例えば、プロパンガスなどを熱源とした温風を鋳型空隙内に吹き込む方法や、予め所望の温度に加熱した電気炉に鋳型を投入する方法により、溶融金属に接触する鋳型（主型及び中子）の表面温度を６０℃〜２５０℃に加熱することにより行われる。鋳型表面温度を加熱する温度は、加熱が十分で、湯周り（溶融金属の流動性）が良好になる観点から６０℃以上であり、８０℃以上が好ましく、１００℃以上がより好ましく、鋳型表面強度が劣化せず、鋳物表面平滑性が維持できる観点から、２５０℃以下であり、２２０℃以下が好ましく、１８０℃以下がより好ましい。好ましい表面温度範囲は、８０℃〜２２０℃、更に１００℃〜１８０℃である。 In the present invention, the method for heating the surface temperature of the mold is not particularly limited, but for example, a method of blowing warm air using propane gas or the like as a heat source into the mold gap, or an electric furnace heated to a desired temperature in advance. This is performed by heating the surface temperature of the mold (main mold and core) in contact with the molten metal to 60 ° C. to 250 ° C. by the method of charging the mold. The temperature at which the mold surface temperature is heated is 60 ° C. or higher, preferably 80 ° C. or higher, more preferably 100 ° C. or higher, from the viewpoint of sufficient heating and good hot water circumference (fluidity of the molten metal). From the viewpoint of maintaining the casting surface smoothness without deteriorating the strength, it is 250 ° C. or lower, preferably 220 ° C. or lower, and more preferably 180 ° C. or lower. A preferable surface temperature range is 80 ° C to 220 ° C, and further 100 ° C to 180 ° C.
なお、ここで表面温度は、市販されている表面温度計を用いて測定することができる。鋳型の表面温度の測定部位は、表面温度計にて計測可能な湯口とあがり口（もしくは押湯口）の２点測定し、その平均値を表面温度とする。測定部位は、なるべく鋳物製品部分が形成される部分に近い方が好ましい。 Here, the surface temperature can be measured using a commercially available surface thermometer. The measurement part of the surface temperature of the mold is measured at two points, a pouring gate and a pouring gate (or pouring gate) that can be measured with a surface thermometer, and the average value is defined as the surface temperature. The measurement site is preferably as close as possible to the portion where the cast product portion is formed.
＜球状鋳物砂＞
本発明では、火炎溶融法にて製造された球状鋳物砂により得られた鋳型が用いられる。
<Spherical casting sand>
In this invention, the casting_mold | template obtained with the spherical casting sand manufactured by the flame melting method is used.
本発明の球状鋳物砂の形状である球状とは、球形度０．８８以上、好ましくは０．９０以上のものをいう。球状であるか否かについては、たとえば、後述の実施例に記載するように、鋳物砂を光学顕微鏡やデジタルスコープ（たとえば、キーエンス社製、ＶＨ−８０００型）等で観察し、判定することができる。 The spherical shape which is the shape of the spherical casting sand of the present invention refers to a sphericity of 0.88 or more, preferably 0.90 or more. Whether or not it is spherical can be determined by observing the foundry sand with an optical microscope or a digital scope (for example, VH-8000, manufactured by Keyence Corporation), for example, as described in Examples below. it can.
本発明の球状鋳物砂の主成分は、従来公知の耐火物及び耐火物原料を火炎溶融法にて球状化したものが用いられ、特に限定されない。これら耐火物及び耐火物原料の中で、耐火性や入手のしやすさなどの観点から、ＳｉＯ2を主成分としたもの、Ａｌ2Ｏ3及びＳｉＯ2を主成分としたもの、ＭｇＯ及びＳｉＯ2を主成分としたものが好ましい。それらの中でも特にＡｌ2Ｏ3及びＳｉＯ2を主成分としたものが好ましい。 The main component of the spherical foundry sand of the present invention is not particularly limited, and conventionally known refractories and refractory raw materials obtained by spheronization by a flame melting method are used. Among these refractories and refractory raw materials, those containing SiO 2 as the main component, those containing Al 2 O 3 and SiO 2 as the main components, MgO and SiO from the viewpoint of fire resistance and availability. Those having 2 as a main component are preferred. Among them, those mainly containing Al 2 O 3 and SiO 2 are preferable.
ここで「主成分」とは、上記成分が合計量で鋳物砂全体の全成分中に６０重量％ 以上含有されていることをいう。主成分の含有量としては、耐火性の向上という観点から、これら成分の合計量は、球状鋳物砂の全成分中、好ましくは８５〜１００重量％、より好ましくは９０〜１００重量％である。 Here, the “main component” means that the above components are contained in a total amount of 60% by weight or more in all the components of the entire foundry sand. As the content of the main component, from the viewpoint of improving fire resistance, the total amount of these components is preferably 85 to 100% by weight, and more preferably 90 to 100% by weight, based on all components of the spherical casting sand.
なお、本発明の球状鋳物砂に主成分以外の成分として含まれ得るものとしては、たとえば、Ｆｅ2Ｏ3、ＴｉＯ2、Ｋ2Ｏ、Ｎａ2Ｏ等の金属酸化物が挙げられる。これらは、出発原料に由来するものである。 Incidentally, as may be included as a component other than the main component in the spherical molding sand of the present invention, for example, Fe 2 O 3, TiO 2 , K 2 O, and metal oxides Na 2 O and the like. These are derived from starting materials.
Ｆｅ2Ｏ3とＴｉＯ2が含まれる場合、それらの含有量としてはそれぞれ５重量％以下が好ましい。また、Ｆｅ2Ｏ3の含有量は２．５重量％以下がより好ましく、２重量％以下がさらに好ましい。Ｋ2ＯとＮａ2Ｏが含まれる場合、それらの含有量としては合計量として３重量％以下が好ましく、より好ましくは１重量％以下である。 When Fe 2 O 3 and TiO 2 are contained, their content is preferably 5% by weight or less. Further, the content of Fe 2 O 3 is more preferably 2.5% by weight or less, and further preferably 2% by weight or less. When K 2 O and Na 2 O are contained, the total content is preferably 3% by weight or less, more preferably 1% by weight or less.
また、Ａｌ2Ｏ3及びＳｉＯ2を主成分とする場合、Ａｌ2Ｏ3／ＳｉＯ2重量比率は１〜１５であることが好ましい。耐火性および鋳物砂の再生効率の向上の観点から、１．２〜１２が好ましく、１．５〜９がより好ましい。また、このＡｌ2Ｏ3及びＳｉＯ2、若しくはＳｉＯ2のみが主成分である場合、主成分以外の成分としてＣａＯとＭｇＯが含まれ得る。その場合、球状鋳物砂の耐火性の向上の観点から、それらの含有量としては合計量として５重量％以下が好ましい。 In the case of mainly composed of Al 2 O 3 and SiO 2, Al 2 O 3 / SiO 2 weight ratio is preferably 1 to 15. From the viewpoint of improvement in fire resistance and casting sand regeneration efficiency, 1.2 to 12 is preferable, and 1.5 to 9 is more preferable. Further, when only Al 2 O 3 and SiO 2 or SiO 2 are the main components, CaO and MgO may be included as components other than the main components. In that case, from the viewpoint of improving the fire resistance of the spherical casting sand, the total content thereof is preferably 5% by weight or less.
また、ＭｇＯ及びＳｉＯ2を主成分とする場合、ＭｇＯ／ＳｉＯ2の重量比率は０．１〜１０が好ましい。球状化のし易さ及び耐蝕性、耐火性及び鋳物砂の再生効率の向上の観点から、０．２〜９が好ましく、０．３〜５がより好ましい。 In the case of the main component MgO and SiO 2, the weight ratio of MgO / SiO 2 is preferably 0.1 to 10 is. From the viewpoints of easiness of spheroidization, corrosion resistance, fire resistance, and improvement in recycle efficiency of foundry sand, 0.2 to 9 is preferable, and 0.3 to 5 is more preferable.
また、このＭｇＯ及びＳｉＯ2が主成分である場合、主成分以外の成分としてＡｌ2Ｏ3が含まれうる。これは原料に由来するが、球状鋳物砂の耐蝕性向上の観点から含有量として１０重量％以下が好ましい。 When MgO and SiO 2 are the main components, Al 2 O 3 can be included as a component other than the main components. Although this originates in a raw material, 10 weight% or less is preferable as content from a viewpoint of the corrosion-resistant improvement of a spherical casting sand.
本発明の球状鋳物砂の平均粒径（ｍｍ）は０．０２〜１．５ｍｍの範囲であることが好ましい。０．０２ｍｍ以上、好ましくは０．０５ｍｍ以上であれば鋳型の製造に要する樹脂量を低減でき、鋳物砂として再生するのが容易となる。一方、１．５ｍｍ以下であれば鋳型の空隙率が小さくなり、鋳型強度の向上に繋がるため好ましい。球状鋳物砂の再生効率を高める観点から、０．０７〜１．５ｍｍが好ましく、一方、鋳型強度を高める観点から、０．０５〜１ｍｍが好ましい。再生効率と鋳型強度の両者を高める観点から、０．０７〜１ｍｍが好ましく、０．０７〜０．５ｍｍがより好ましく、０．０７〜０．３５ｍｍがさらに好ましい。 The average particle size (mm) of the spherical casting sand of the present invention is preferably in the range of 0.02 to 1.5 mm. If it is 0.02 mm or more, preferably 0.05 mm or more, the amount of resin required for the production of the mold can be reduced, and it becomes easy to regenerate as foundry sand. On the other hand, if it is 1.5 mm or less, the porosity of the mold is reduced, which leads to improvement of the mold strength. From the viewpoint of improving the recycle efficiency of the spherical casting sand, 0.07 to 1.5 mm is preferable, and from the viewpoint of increasing the mold strength, 0.05 to 1 mm is preferable. From the viewpoint of increasing both the regeneration efficiency and the mold strength, 0.07 to 1 mm is preferable, 0.07 to 0.5 mm is more preferable, and 0.07 to 0.35 mm is more preferable.
前記平均粒径は以下のようにして求めることができる。すなわち、球状鋳物砂粒子の粒子投影断面からの球形度＝１の場合は直径（ｍｍ）を測定し、一方、球形度＜１の場合は球状鋳物砂粒子の長軸径（ｍｍ）と短軸径（ｍｍ）を測定して（長軸径＋短軸径）／２を求め、任意の１００個の球状鋳物砂粒子につき、それぞれ得られた値を平均して平均粒径（ｍｍ）とする。長軸径と短軸径は、以下のように定義される。粒子を平面上に安定させ、その粒子の平面上への投影像を２本の平行線ではさんだとき、その平行線の間隔が最小となる粒子の幅を短軸径といい、一方、この平行線に直角な方向の２本の平行線で粒子をはさむときの距離を長軸径という。 The average particle diameter can be determined as follows. That is, the diameter (mm) is measured when the sphericity from the particle projection cross section of the spherical casting sand particles is 1, while the major axis diameter (mm) and the minor axis of the spherical casting sand particles are measured when the sphericity <1. The diameter (mm) is measured to determine (major axis diameter + minor axis diameter) / 2, and the average value of the average particle diameter (mm) is obtained for any 100 spherical cast sand particles. . The major axis diameter and the minor axis diameter are defined as follows. When the particle is stabilized on a plane and the projected image of the particle on the plane is sandwiched between two parallel lines, the width of the particle that minimizes the distance between the parallel lines is called the minor axis diameter. The distance when a particle is sandwiched between two parallel lines in a direction perpendicular to the line is called the major axis diameter.
なお、球状鋳物砂粒子の長軸径と短軸径は、光学顕微鏡またはデジタルスコープ（例えば、キーエンス社製、ＶＨ−８０００型）により該粒子の像（写真）を得、得られた像を画像解析することにより求めることができる。また、球形度は、得られた像を画像解析することにより、該粒子の粒子投影断面の面積および該断面の周囲長を求め、次いで、〔粒子投影断面の面積（ｍｍ2）と同じ面積の真円の円周長（ｍｍ）〕／〔粒子投影断面の周囲長（ｍｍ）〕を計算し、任意の５０個の球状鋳物砂粒子につき、それぞれ得られた値を平均して求める。 In addition, the major axis diameter and minor axis diameter of the spherical casting sand particles are obtained by obtaining an image (photograph) of the particles with an optical microscope or a digital scope (for example, VH-8000 type, manufactured by Keyence Corporation). It can be obtained by analysis. The sphericity is obtained by image analysis of the obtained image to determine the area of the particle projection cross section of the particle and the perimeter of the cross section, and then [the area of the same area as the area of the particle projection cross section (mm 2 )] The circumference of the perfect circle (mm)] / [perimeter of the particle projection cross section (mm)] is calculated, and the obtained values are averaged for any of 50 spheroidal molding sand particles.
本発明の球状鋳物砂としては、その球形度が、０．９５以上であるものが好ましく、０．９８以上であるものがより好ましく、０．９９以上であるものがさらに好ましい。 The spherical casting sand of the present invention preferably has a sphericity of 0.95 or more, more preferably 0.98 or more, and even more preferably 0.99 or more.
本発明の球状鋳物砂は火炎溶融法により得られるものである。従って、球形度が高く、緻密であるという構造的特徴を有する。当該構造的特徴は、流動性、鋳型強度、鋳造された鋳物の表面平滑性の向上に大きく寄与する。 The spherical casting sand of the present invention is obtained by a flame melting method. Therefore, it has a structural feature of high sphericity and denseness. The structural feature greatly contributes to improvement of fluidity, mold strength, and surface smoothness of a cast product.
また、本発明の球状鋳物砂の吸水率（重量％）としては、鋳型の製造の際に使用する樹脂の鋳物砂内部への吸収による樹脂使用量の増加の抑制や、鋳型強度の向上等の観点から、３重量％以下が好ましく、０．８重量％以下がより好ましく、０．５重量％以下がさらに好ましく、０．３重量％以下が特に好ましい。吸水率はＪＩＳ Ａ１１０９細骨材の吸水率測定方法に従って測定することができる。 Further, the water absorption rate (% by weight) of the spherical casting sand according to the present invention includes an increase in the amount of resin used due to absorption of the resin used in the production of the mold into the casting sand, an improvement in the mold strength, etc. From the viewpoint, it is preferably 3% by weight or less, more preferably 0.8% by weight or less, further preferably 0.5% by weight or less, and particularly preferably 0.3% by weight or less. The water absorption can be measured according to the method for measuring the water absorption of JIS A1109 fine aggregate.
なお、球状鋳物砂の吸水率は、火炎溶融法により該砂を調製した場合、該方法以外の焼成方法により調製した砂と比べて、同じ球形度であれば、通常、吸水率は低くなる。 In addition, the water absorption rate of spherical cast sand is usually lower when the sand is prepared by a flame melting method and the same sphericity as compared with sand prepared by a firing method other than the method.
一方、本発明の球状鋳物砂の球形度が０．９８以上である場合、かかる球状鋳物砂が、珪砂等の流動性の低い公知の鋳物砂との混合物中に好ましくは５０体積％以上含有されておれば、該混合物からなる鋳物砂は充分に本発明の所望の効果を発揮し得る。すなわち、前記のような公知の鋳物砂に本発明の球状鋳物砂を徐々に添加していけば、添加量に応じて本発明の所望の効果を発揮するようになるが、前記混合物からなる鋳物砂中に、前記所定の球形度を有する本発明の球状鋳物砂が５０体積％以上含まれると、その効果は顕著になる。なお、当該混合物からなる鋳物砂中の、球形度が０．９８以上である本発明の球状鋳物砂の含有量としては、より好ましくは６０体積％以上、さらに好ましくは８０体積％以上である。従って、本発明の球状鋳物砂としては、その利用性に優れることから、球形度が０．９８以上であるものが特に好適である。また、かかる球状鋳物砂を５０体積％以上含む鋳物砂は、本発明の球状鋳物砂と同等の効果を発揮し得ることから、かかる鋳物砂も本発明に包含される。 On the other hand, when the sphericity of the spherical casting sand of the present invention is 0.98 or more, the spherical casting sand is preferably contained in a mixture with known casting sand having low fluidity such as silica sand in an amount of 50% by volume or more. In this case, the foundry sand made of the mixture can sufficiently exhibit the desired effect of the present invention. That is, if the spherical foundry sand of the present invention is gradually added to the known foundry sand as described above, the desired effect of the present invention will be exhibited depending on the amount added, but the cast comprising the above mixture. The effect becomes remarkable when 50% by volume or more of the spherical cast sand of the present invention having the predetermined sphericity is contained in the sand. In addition, as content of the spherical foundry sand of this invention whose sphericity is 0.98 or more in the foundry sand which consists of the said mixture, More preferably, it is 60 volume% or more, More preferably, it is 80 volume% or more. Accordingly, as the spherical casting sand of the present invention, one having a sphericity of 0.98 or more is particularly suitable because of its excellent utility. Further, since the foundry sand containing 50% by volume or more of the spherical foundry sand can exhibit the same effect as the spherical foundry sand of the present invention, such foundry sand is also included in the present invention.
さらに、本発明の球状鋳物砂の非晶化度としては、５５〜１００％が好ましく、より好ましくは７０〜１００％である。非晶化度が大きいほど、熱膨張率が小さくなるため焼着が発生しにくくなるためである。 Furthermore, the amorphous degree of the spheroidal foundry sand of the present invention is preferably 55 to 100%, more preferably 70 to 100%. This is because the larger the degree of amorphousness, the smaller the coefficient of thermal expansion, so that it is difficult for seizure to occur.
非晶化度の制御方法としては、例えば火炎中において処理し、急冷させる方法がある。また、一旦結晶化したものを熱処理と冷却処理にて非結晶化させる方法も考えられる。 As a method for controlling the degree of amorphization, for example, there is a method of treating in a flame and quenching. A method of crystallizing the crystallized material by heat treatment and cooling treatment is also conceivable.
非晶化度は、下記に示されるＸ線回折から得られる数値によって求めることができる。
＜Ｘ線回折＞
鋳物砂を乳鉢で粉砕し、粉末Ｘ線回折装置のＸ線ガラスホルダーに圧着して測定する。粉末Ｘ線回折装置は、理学電気製MultiFlex（光源ＣｕＫα線、管電圧４０ｋｖ、管電流４０ｍＡ）を用い、２θ＝５〜９０°の範囲で走査間隔０．０１°、走査速度２°／ｍｉｎ、スリットＤＳ１、ＳＳ１、ＲＳ０．３ｍｍにて行う。２θ＝１０°〜５０°の範囲で、低角度側及び高角度側のＸ線強度を直線で結び、直線下の面積をバックグラウンドとし、機器付属のソフトを用いて結晶化度を求め、１００から引いて非晶化度とした。具体的には、バックグラウンドより上の面積について、非晶質ピーク（ハロー）と各結晶性成分をカーブフィッティングにより分離し、それぞれの面積を求め、下記式にて非晶化度（％）を計算する。
非晶化度（％）＝ハローの面積／（結晶性成分面積＋ハロー面積）×１００
The degree of amorphousness can be determined by a numerical value obtained from the X-ray diffraction shown below.
<X-ray diffraction>
The foundry sand is pulverized in a mortar, and measured by pressing it onto an X-ray glass holder of a powder X-ray diffraction apparatus. The powder X-ray diffractometer uses Rigaku Denki MultiFlex (light source CuKα ray, tube voltage 40 kv, tube current 40 mA), a scan interval of 0.01 ° in a range of 2θ = 5 to 90 °, a scan speed of 2 ° / min, The slits DS1, SS1, and RS are 0.3 mm. In the range of 2θ = 10 ° to 50 °, the X-ray intensities on the low angle side and the high angle side are connected with a straight line, the area under the straight line is set as the background, and the degree of crystallinity is obtained using the software attached to the device. Was taken as the degree of amorphousness. Specifically, for the area above the background, the amorphous peak (halo) and each crystalline component are separated by curve fitting, the respective areas are obtained, and the degree of amorphousness (%) is calculated by the following formula. calculate.
Amorphous degree (%) = Halo area / (Crystalline component area + Halo area) × 100
前記の通り、本発明の球状鋳物砂は、特開２００４−２０２５７７号に例示されるような火炎溶融法により製造される。即ち、例えば平均粒径が０．０５〜２ｍｍの耐火物粉末粒子を出発原料とし、当該粉末粒子を酸素等のキャリアガスに分散させ、下記火炎中で溶融して球状化する。用いる火炎はプロパン、ブタン、メタン、天然液化ガス、ＬＰＧ、重油、灯油、軽油、微粉炭等の燃料を酸素と燃焼させることによって発生させたものや、Ｎ2不活性ガス等を電離させて生じるプラズマジェット火炎などが使用できる。特に、本発明の球状鋳物砂の製造に当たっては、０．０３〜２ｍｍの平均粒径をもつ粉末粒子を出発原料とし、火炎中で溶融し球状化しても構わないし、異なる粒径の粉末粒子を火炎溶融処理した後、分級して得てもかまわない。本発明の球状鋳物砂の平均粒子径としては０．０２〜１．５ｍｍが好ましい。 As described above, the spheroidal sand of the present invention is produced by a flame melting method as exemplified in JP-A No. 2004-202577. That is, for example, refractory powder particles having an average particle diameter of 0.05 to 2 mm are used as a starting material, and the powder particles are dispersed in a carrier gas such as oxygen and melted into a sphere to form a sphere. Occurs flame propane, butane, methane, natural liquefied gas, LPG, heavy oil, kerosene, gas oil, and that is generated by burning the fuel oxygen pulverized coal etc., ionizes the N 2 inert gas or the like used Plasma jet flames can be used. In particular, in the production of the spherical molding sand of the present invention, powder particles having an average particle size of 0.03 to 2 mm may be used as a starting material, and may be melted and spheroidized in a flame. After the flame melting treatment, classification may be performed. The average particle diameter of the spherical casting sand of the present invention is preferably 0.02 to 1.5 mm.
また、球状鋳物砂の耐火度はＳＫ１７（１４８０℃）以上が好ましく、特にＳＫ３７（１８２５℃）以上であることが好ましい。この耐火度は、ＪＩＳ Ｒ ２２０４に基づくゼーゲルコーン法により測定したものである。したがって、本発明に用いられる球状鋳物砂は、融点が１２００℃〜２２００℃以下の無機鉱物が好ましい。 Further, the fire resistance of the spherical casting sand is preferably SK17 (1480 ° C.) or more, and particularly preferably SK37 (1825 ° C.) or more. This fire resistance is measured by the Seegel cone method based on JIS R 2204. Therefore, the spherical casting sand used in the present invention is preferably an inorganic mineral having a melting point of 1200 ° C. to 2200 ° C. or less.
本発明の火炎溶融法にて製造された球状鋳物砂を用いて鋳型を得る方法としては、球状鋳物砂に対して、従来公知の鋳型バインダー、例えば、粘土、水ガラス、シリカゾル、無機塩、エチルシリケート等の無機質バインダー、フラン樹脂、フェノール樹脂、アルカリフェノール樹脂、フェノールウレタン樹脂、エポキシ樹脂、不飽和ポリエステル樹脂やメチレンジアクリルアミド等の不飽和基を有する樹脂等の有機バインダーを用いて、それぞれ従来公知の硬化方法により鋳型を製造することができる。本発明の効果が発現する観点から、鋳型バインダーとしては、フラン樹脂、アルカリフェノール樹脂、フェノールウレタン樹脂、フェノール樹脂が好適であり、鋳型としては、フラン鋳型、アルカリフェノール鋳型、フェノールウレタン鋳型、シェルモールド鋳型が好適である。これらバインダーは、本発明の鋳型砂１００重量部に対して、通常０．０５〜１０重量部添加するのが好適である。また、従来公知のシランカップリング剤、添加剤等を用いても構わない。 As a method of obtaining a mold using the spherical casting sand produced by the flame melting method of the present invention, conventionally known mold binders such as clay, water glass, silica sol, inorganic salt, ethyl are used. Inorganic binders such as silicates, organic binders such as furan resins, phenol resins, alkali phenol resins, phenol urethane resins, epoxy resins, unsaturated polyester resins and resins having unsaturated groups such as methylene diacrylamide are conventionally known. A mold can be produced by the curing method. From the viewpoint of manifesting the effects of the present invention, as the mold binder, furan resin, alkali phenol resin, phenol urethane resin, and phenol resin are suitable. As the mold, furan mold, alkali phenol mold, phenol urethane mold, shell mold A mold is preferred. These binders are preferably added in an amount of usually 0.05 to 10 parts by weight with respect to 100 parts by weight of the mold sand of the present invention. Moreover, you may use a conventionally well-known silane coupling agent, an additive, etc.
本発明の鋳物の材質としては、鋳鉄（ダクタイル含む）、鋳鋼、アルミ合金、銅合金など全ての材質に適用可能であり、本発明の効果を発現し易い観点から、ダクタイル鋳鉄、鋳鋼、アルミ合金が好ましい。 The cast material of the present invention can be applied to all materials such as cast iron (including ductile), cast steel, aluminum alloy, copper alloy, etc., and from the viewpoint of easily manifesting the effects of the present invention, ductile cast iron, cast steel, aluminum alloy Is preferred.
本発明の製造方法で得られる鋳物としては、薄肉で複雑な形状を有し、かつ、鋳肌表面の美しさ、寸法精度が要求される、薄肉鋳物が挙げられる。特に、本発明の方法は、気体や液体などの流体が通過する面を有する部品の製造や、これまでは複数の部品を組合せて一体化していた部品を一体的に製造する際に好適に用いられる。 The casting obtained by the production method of the present invention includes a thin casting that has a thin and complicated shape and that requires a beautiful casting surface and dimensional accuracy. In particular, the method of the present invention is suitably used when manufacturing parts having a surface through which a fluid such as gas or liquid passes, or when integrally manufacturing parts that have been combined with a plurality of parts. It is done.
具体的には、水道や油圧のバルプや配管部品、フィン部分や複雑なモーター部品（ケーシング）、平滑性が要求されるポンプ部品（インペラーなど）やエンジン部品（フレーム）、金型、駆動伝達装置の部品、工作機械部品、建築部材などが挙げられ、これらの中で薄肉部分を有するものである。 Specifically, water and hydraulic valves and piping parts, fins and complex motor parts (casing), pump parts (such as impellers) and engine parts (frames) that require smoothness, molds, and drive transmission devices Parts, machine tool parts, building members, etc., and among these, have a thin portion.
試験例１及び比較試験例１〜２
表１に示す鋳物砂を用い、アルカリフェノール樹脂（商品名カオーステップＳ−６６０、花王クエーカー（株）製）を鋳物砂１００重量部に対して１．０重量部、およびアルカリフェノール硬化剤（商品名カオーステップＱＸ−１３０、花王クエーカー（株）製）をアルカリフェノール樹脂１００質量部に対して３０重量部添加し、高さ５０ｍｍ、直径５０ｍｍの円筒形のテストピースを作製した。これを２４時間放置したのち、２００℃にて９０分処理した。その後、表面温度２００℃の状態で、該テストピースの表面強度の測定を、スクラッチハードネステスター（引っ掻き強度試験器）にて行った。熱処理前の表面強度も測定しておき、以下の式により、表面強度保持率（％）を求めた。結果を表１に示す。なお、比較試験例１〜２は、共にアルカリフェノール樹脂の量を鋳物砂１００重量部に対して１．５重量部とした。
表面強度保持率（％）＝１００×熱処理後の表面強度／熱処理前の表面強度
Test Example 1 and Comparative Test Examples 1-2
Using the foundry sand shown in Table 1, 1.0 part by weight of alkali phenol resin (trade name Kao Step S-660, manufactured by Kao Quaker Co., Ltd.) with respect to 100 parts by weight of foundry sand, and alkali phenol hardener (product) 30 parts by weight of the name Kao Step QX-130, manufactured by Kao Quaker Co., Ltd. was added to 100 parts by weight of the alkali phenol resin to produce a cylindrical test piece having a height of 50 mm and a diameter of 50 mm. This was left for 24 hours and then treated at 200 ° C. for 90 minutes. Thereafter, the surface strength of the test piece was measured with a scratch hard tester (scratch strength tester) at a surface temperature of 200 ° C. The surface strength before heat treatment was also measured, and the surface strength retention rate (%) was determined by the following formula. The results are shown in Table 1. In Comparative Test Examples 1 and 2, the amount of the alkali phenol resin was 1.5 parts by weight with respect to 100 parts by weight of the foundry sand.
Surface strength retention (%) = 100 × surface strength after heat treatment / surface strength before heat treatment
（注）表１中の鋳物砂は以下のものである。
・球状鋳物砂：下記製造例で得られた球状鋳物砂
（製造例）
Ａｌ2Ｏ3とＳｉＯ2を合計量で９７重量％含有する、Ａｌ2Ｏ3／ＳｉＯ2重量比率が１．７、含水率が０重量％、平均粒径が０．３１ｍｍ、長軸径／短軸径比が１．５、のムライト粉末（柴田セラミックス製合成ムライト粉末）を出発原料とし、当該粉末を、酸素をキャリアガスとして用い、ＬＰＧ（プロパンガス）を対酸素比（容量比）１．１で燃焼させた火炎（約２０００℃）中に投入し、単分散した球状鋳物砂を得た。得られた鋳物砂は、Ａｌ2Ｏ3とＳｉＯ2を合計量で９７重量％含有しており、Ａｌ2Ｏ3／ＳｉＯ2重量比率が１．７、平均粒径が０．２６ｍｍ、球形度が０．９９、吸水率が０重量％、粒子密度が２．９ｇ／ｃｍ3、耐火度はＳＫ３７であった。
・粒状焼結砂：商品名セラビーズ＃８５０（伊藤忠セラテック社製）
・珪砂：オーストラリア産珪砂（フラタリー）
(Note) The sand found in Table 1 is as follows.
・ Spherical casting sand: Spherical casting sand obtained in the following production example (production example)
97% by weight of Al 2 O 3 and SiO 2 in total, Al 2 O 3 / SiO 2 weight ratio is 1.7, water content is 0% by weight, average particle size is 0.31 mm, major axis diameter / A mullite powder (synthetic mullite powder manufactured by Shibata Ceramics) having a minor axis diameter ratio of 1.5 is used as a starting material, the powder is used as a carrier gas, and LPG (propane gas) is used in an oxygen ratio (volume ratio) of 1 Was put into a flame (about 2000 ° C.) burned in 1. to obtain monodispersed spherical casting sand. The obtained foundry sand contains 97% by weight of Al 2 O 3 and SiO 2 in total amount, the Al 2 O 3 / SiO 2 weight ratio is 1.7, the average particle size is 0.26 mm, and the sphericity Was 0.99, the water absorption was 0% by weight, the particle density was 2.9 g / cm 3 , and the fire resistance was SK37.
-Granular sintered sand: Trade name Cerabeads # 850 (manufactured by ITOCHU CERATECH)
・ Silica sand: Australian quartz sand (flattery)
実施例１〜４、比較例１及び２
図１に示した形状の鋳型を、ＡＦＳ−ＧＦＮ（粒度分布）が約８０の火炎溶融法により調製された球状鋳物砂、アルカリフェノール樹脂（商品名カオーステップＳ−６６０、花王クエーカー製）を鋳物砂１００重量部に対して１．０重量部、およびアルカリフェノール用硬化剤（商品名カオーステップＯＸ−１３０、花王クエーカー製）をアルカリフェノール樹脂１００重量部に対して３０重量部の割合で混合した混練砂から成型した。この鋳型を所望の温度に設定された電気炉に投入して２０時間加温を行い、表２に示す通りの鋳型表面温度になるように調整した。
Examples 1-4, Comparative Examples 1 and 2
A casting mold having the shape shown in FIG. 1 is cast from spherical casting sand prepared by a flame melting method with an AFS-GFN (particle size distribution) of about 80, and an alkali phenol resin (trade name Kao Step S-660, manufactured by Kao Quaker). 1.0 part by weight with respect to 100 parts by weight of sand and a curing agent for alkali phenol (trade name Kao Step OX-130, manufactured by Kao Quaker Co., Ltd.) were mixed at a ratio of 30 parts by weight with respect to 100 parts by weight of the alkali phenol resin. Molded from kneaded sand. This mold was put into an electric furnace set at a desired temperature and heated for 20 hours to adjust the mold surface temperature as shown in Table 2.
電気炉から取り出したこの鋳型に、直ちに、材質ＦＣ−２５０、鋳込み温度１４００℃にて鋳造を行い、図２に示す鋳物を製造し、鋳物表面の平滑性を目視観察し、平滑性が同等の比較用表面あらさ標準片（ＪＩＳ Ｂ ０６５９記載）を選定し、その区分値により評価した。結果を表２に示す。 This mold taken out from the electric furnace is immediately cast at a material FC-250 and a casting temperature of 1400 ° C. to produce a casting shown in FIG. 2, and the smoothness of the casting surface is visually observed, and the smoothness is equal. A comparative surface roughness standard piece (described in JIS B 0659) was selected and evaluated based on its classification value. The results are shown in Table 2.
比較例３
実施例１の球状鋳物砂に代えて、粒状焼結品（商品名セラビーズ＃８５０、伊藤忠セラテック社製）を用い、樹脂添加量を鋳物砂１００重量部に対して１．５重量部とした以外は、実施例１と同様に鋳造を行い、同様の評価を行った。結果を表２に示す。
Comparative Example 3
A granular sintered product (trade name Cerabeads # 850, manufactured by ITOCHU CERATECH) was used in place of the spherical foundry sand of Example 1, and the resin addition amount was 1.5 parts by weight with respect to 100 parts by weight of foundry sand. Were cast in the same manner as in Example 1 and evaluated in the same manner. The results are shown in Table 2.
比較例４
実施例１の球状鋳物砂に代えて、オーストラリア産珪砂（フラタリー）を用いた以外は、実施例１と同様に鋳造を行い、同様の評価を行った。結果を表２に示す。
Comparative Example 4
Casting was performed in the same manner as in Example 1 except that Australian quartz sand (flattery) was used in place of the spherical casting sand of Example 1, and the same evaluation was performed. The results are shown in Table 2.
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| JP2011092991A (en) * | 2009-11-02 | 2011-05-12 | Sanei Shirika:Kk | Casting sand and method for producing the same, and mold using the casting sand |
| JP5347077B1 (en) * | 2013-03-19 | 2013-11-20 | テクノメタル株式会社 | Sand mold casting method |
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| JPH08332547A (en) * | 1995-06-09 | 1996-12-17 | Juki Corp | Casting method and mold and its production |
| JPH0999340A (en) * | 1995-10-03 | 1997-04-15 | Sugitani Kinzoku Kogyo Kk | Die member for casting metal, and aggregate used for the die member |
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