JP4877923B2 - Spherical casting sand - Google Patents
Spherical casting sand Download PDFInfo
- Publication number
- JP4877923B2 JP4877923B2 JP2006020568A JP2006020568A JP4877923B2 JP 4877923 B2 JP4877923 B2 JP 4877923B2 JP 2006020568 A JP2006020568 A JP 2006020568A JP 2006020568 A JP2006020568 A JP 2006020568A JP 4877923 B2 JP4877923 B2 JP 4877923B2
- Authority
- JP
- Japan
- Prior art keywords
- weight
- sand
- less
- casting
- spherical
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 239000004576 sand Substances 0.000 title claims description 151
- 238000005266 casting Methods 0.000 title claims description 110
- 238000000034 method Methods 0.000 claims description 63
- 239000011230 binding agent Substances 0.000 claims description 53
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 40
- 239000002245 particle Substances 0.000 claims description 35
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 22
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 21
- 238000010521 absorption reaction Methods 0.000 claims description 18
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims description 17
- 238000004519 manufacturing process Methods 0.000 claims description 17
- 238000002844 melting Methods 0.000 claims description 14
- 230000008018 melting Effects 0.000 claims description 14
- 239000003513 alkali Substances 0.000 claims description 13
- 238000002156 mixing Methods 0.000 claims description 8
- 239000003110 molding sand Substances 0.000 claims description 8
- 230000003746 surface roughness Effects 0.000 claims description 7
- 229910010413 TiO 2 Inorganic materials 0.000 claims description 5
- 238000010828 elution Methods 0.000 claims description 5
- 230000008569 process Effects 0.000 claims description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 149
- -1 polyol compound Chemical class 0.000 description 33
- 229920001228 polyisocyanate Polymers 0.000 description 30
- 239000005056 polyisocyanate Substances 0.000 description 30
- 239000007789 gas Substances 0.000 description 26
- 229920005862 polyol Polymers 0.000 description 25
- 150000001875 compounds Chemical class 0.000 description 22
- 239000000203 mixture Substances 0.000 description 22
- 230000007547 defect Effects 0.000 description 20
- 239000000243 solution Substances 0.000 description 20
- 239000003960 organic solvent Substances 0.000 description 18
- 239000002253 acid Substances 0.000 description 13
- 239000005011 phenolic resin Substances 0.000 description 13
- ZMANZCXQSJIPKH-UHFFFAOYSA-N Triethylamine Chemical compound CCN(CC)CC ZMANZCXQSJIPKH-UHFFFAOYSA-N 0.000 description 12
- 239000002904 solvent Substances 0.000 description 12
- 238000006243 chemical reaction Methods 0.000 description 11
- 238000001723 curing Methods 0.000 description 11
- 238000000465 moulding Methods 0.000 description 11
- 230000000052 comparative effect Effects 0.000 description 8
- 230000000694 effects Effects 0.000 description 7
- 238000004898 kneading Methods 0.000 description 7
- 239000003054 catalyst Substances 0.000 description 6
- 238000011156 evaluation Methods 0.000 description 6
- 238000011049 filling Methods 0.000 description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 238000006386 neutralization reaction Methods 0.000 description 6
- 238000005406 washing Methods 0.000 description 6
- 150000001412 amines Chemical class 0.000 description 5
- 238000005452 bending Methods 0.000 description 5
- 230000006872 improvement Effects 0.000 description 5
- 239000012948 isocyanate Substances 0.000 description 5
- 229920001568 phenolic resin Polymers 0.000 description 5
- 150000003077 polyols Chemical class 0.000 description 5
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 4
- 238000005273 aeration Methods 0.000 description 4
- 150000002513 isocyanates Chemical class 0.000 description 4
- 229910052760 oxygen Inorganic materials 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 230000008929 regeneration Effects 0.000 description 4
- 238000011069 regeneration method Methods 0.000 description 4
- 229920005989 resin Polymers 0.000 description 4
- 239000011347 resin Substances 0.000 description 4
- 239000011734 sodium Substances 0.000 description 4
- 150000003512 tertiary amines Chemical class 0.000 description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 229910052802 copper Inorganic materials 0.000 description 3
- 239000010949 copper Substances 0.000 description 3
- XPFVYQJUAUNWIW-UHFFFAOYSA-N furfuryl alcohol Chemical compound OCC1=CC=CO1 XPFVYQJUAUNWIW-UHFFFAOYSA-N 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 230000035699 permeability Effects 0.000 description 3
- 239000003208 petroleum Substances 0.000 description 3
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 3
- 230000000704 physical effect Effects 0.000 description 3
- 229920002857 polybutadiene Polymers 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- 238000003756 stirring Methods 0.000 description 3
- 238000004448 titration Methods 0.000 description 3
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 2
- UPMLOUAZCHDJJD-UHFFFAOYSA-N 4,4'-Diphenylmethane Diisocyanate Chemical compound C1=CC(N=C=O)=CC=C1CC1=CC=C(N=C=O)C=C1 UPMLOUAZCHDJJD-UHFFFAOYSA-N 0.000 description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 2
- 239000004606 Fillers/Extenders Substances 0.000 description 2
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 description 2
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000004721 Polyphenylene oxide Substances 0.000 description 2
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- 239000006087 Silane Coupling Agent Substances 0.000 description 2
- 239000000443 aerosol Substances 0.000 description 2
- 125000001931 aliphatic group Chemical group 0.000 description 2
- 229910052783 alkali metal Inorganic materials 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 239000007864 aqueous solution Substances 0.000 description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 2
- YCIMNLLNPGFGHC-UHFFFAOYSA-N catechol Chemical compound OC1=CC=CC=C1O YCIMNLLNPGFGHC-UHFFFAOYSA-N 0.000 description 2
- 239000003638 chemical reducing agent Substances 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000004512 die casting Methods 0.000 description 2
- XIRNKXNNONJFQO-UHFFFAOYSA-N ethyl hexadecanoate Chemical compound CCCCCCCCCCCCCCCC(=O)OCC XIRNKXNNONJFQO-UHFFFAOYSA-N 0.000 description 2
- 238000010304 firing Methods 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 229910001867 inorganic solvent Inorganic materials 0.000 description 2
- 239000003049 inorganic solvent Substances 0.000 description 2
- IQPQWNKOIGAROB-UHFFFAOYSA-N isocyanate group Chemical group [N-]=C=O IQPQWNKOIGAROB-UHFFFAOYSA-N 0.000 description 2
- HJOVHMDZYOCNQW-UHFFFAOYSA-N isophorone Chemical compound CC1=CC(=O)CC(C)(C)C1 HJOVHMDZYOCNQW-UHFFFAOYSA-N 0.000 description 2
- 229910052749 magnesium Inorganic materials 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 150000004702 methyl esters Chemical class 0.000 description 2
- 239000012454 non-polar solvent Substances 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- AQSJGOWTSHOLKH-UHFFFAOYSA-N phosphite(3-) Chemical class [O-]P([O-])[O-] AQSJGOWTSHOLKH-UHFFFAOYSA-N 0.000 description 2
- 238000005554 pickling Methods 0.000 description 2
- 239000002798 polar solvent Substances 0.000 description 2
- 229920000570 polyether Polymers 0.000 description 2
- 239000011819 refractory material Substances 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 238000004904 shortening Methods 0.000 description 2
- 150000004760 silicates Chemical class 0.000 description 2
- LIVNPJMFVYWSIS-UHFFFAOYSA-N silicon monoxide Chemical compound [Si-]#[O+] LIVNPJMFVYWSIS-UHFFFAOYSA-N 0.000 description 2
- 239000007858 starting material Substances 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- MCTWTZJPVLRJOU-UHFFFAOYSA-N 1-methyl-1H-imidazole Chemical compound CN1C=CN=C1 MCTWTZJPVLRJOU-UHFFFAOYSA-N 0.000 description 1
- AQIIVEISJBBUCR-UHFFFAOYSA-N 4-(3-phenylpropyl)pyridine Chemical compound C=1C=NC=CC=1CCCC1=CC=CC=C1 AQIIVEISJBBUCR-UHFFFAOYSA-N 0.000 description 1
- HVCNXQOWACZAFN-UHFFFAOYSA-N 4-ethylmorpholine Chemical compound CCN1CCOCC1 HVCNXQOWACZAFN-UHFFFAOYSA-N 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- ROFVEXUMMXZLPA-UHFFFAOYSA-N Bipyridyl Chemical group N1=CC=CC=C1C1=CC=CC=N1 ROFVEXUMMXZLPA-UHFFFAOYSA-N 0.000 description 1
- 229910001208 Crucible steel Inorganic materials 0.000 description 1
- ZAFNJMIOTHYJRJ-UHFFFAOYSA-N Diisopropyl ether Chemical compound CC(C)OC(C)C ZAFNJMIOTHYJRJ-UHFFFAOYSA-N 0.000 description 1
- UDSFAEKRVUSQDD-UHFFFAOYSA-N Dimethyl adipate Chemical compound COC(=O)CCCCC(=O)OC UDSFAEKRVUSQDD-UHFFFAOYSA-N 0.000 description 1
- MUXOBHXGJLMRAB-UHFFFAOYSA-N Dimethyl succinate Chemical compound COC(=O)CCC(=O)OC MUXOBHXGJLMRAB-UHFFFAOYSA-N 0.000 description 1
- LVGKNOAMLMIIKO-UHFFFAOYSA-N Elaidinsaeure-aethylester Natural products CCCCCCCCC=CCCCCCCCC(=O)OCC LVGKNOAMLMIIKO-UHFFFAOYSA-N 0.000 description 1
- 239000005057 Hexamethylene diisocyanate Substances 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 description 1
- 229920000265 Polyparaphenylene Polymers 0.000 description 1
- 239000006004 Quartz sand Substances 0.000 description 1
- 235000019484 Rapeseed oil Nutrition 0.000 description 1
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical compound CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 description 1
- 238000000563 Verneuil process Methods 0.000 description 1
- 241000212749 Zesius chrysomallus Species 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- DGEZNRSVGBDHLK-UHFFFAOYSA-N [1,10]phenanthroline Chemical compound C1=CN=C2C3=NC=CC=C3C=CC2=C1 DGEZNRSVGBDHLK-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 239000012190 activator Substances 0.000 description 1
- 238000007259 addition reaction Methods 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 150000001299 aldehydes Chemical class 0.000 description 1
- 125000002723 alicyclic group Chemical group 0.000 description 1
- 150000001340 alkali metals Chemical class 0.000 description 1
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 1
- 150000004996 alkyl benzenes Chemical class 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000003669 anti-smudge Effects 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 230000003796 beauty Effects 0.000 description 1
- FDQSRULYDNDXQB-UHFFFAOYSA-N benzene-1,3-dicarbonyl chloride Chemical compound ClC(=O)C1=CC=CC(C(Cl)=O)=C1 FDQSRULYDNDXQB-UHFFFAOYSA-N 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 1
- 239000004327 boric acid Substances 0.000 description 1
- 150000001639 boron compounds Chemical class 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- 239000001273 butane Substances 0.000 description 1
- 150000001735 carboxylic acids Chemical class 0.000 description 1
- 239000012159 carrier gas Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 150000001805 chlorine compounds Chemical class 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 238000006482 condensation reaction Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000010908 decantation Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- MHDVGSVTJDSBDK-UHFFFAOYSA-N dibenzyl ether Chemical compound C=1C=CC=CC=1COCC1=CC=CC=C1 MHDVGSVTJDSBDK-UHFFFAOYSA-N 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- XTDYIOOONNVFMA-UHFFFAOYSA-N dimethyl pentanedioate Chemical compound COC(=O)CCCC(=O)OC XTDYIOOONNVFMA-UHFFFAOYSA-N 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical group 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 1
- 230000008034 disappearance Effects 0.000 description 1
- 239000003480 eluent Substances 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 150000002170 ethers Chemical class 0.000 description 1
- WDPYDDUVWLUIDM-UHFFFAOYSA-N ethyl carbamate;phenol Chemical compound CCOC(N)=O.OC1=CC=CC=C1 WDPYDDUVWLUIDM-UHFFFAOYSA-N 0.000 description 1
- LVGKNOAMLMIIKO-QXMHVHEDSA-N ethyl oleate Chemical compound CCCCCCCC\C=C/CCCCCCCC(=O)OCC LVGKNOAMLMIIKO-QXMHVHEDSA-N 0.000 description 1
- 229940093471 ethyl oleate Drugs 0.000 description 1
- 229940067592 ethyl palmitate Drugs 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 239000003205 fragrance Substances 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 239000000295 fuel oil Substances 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
- 125000000524 functional group Chemical group 0.000 description 1
- 238000005469 granulation Methods 0.000 description 1
- 230000003179 granulation Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- RRAMGCGOFNQTLD-UHFFFAOYSA-N hexamethylene diisocyanate Chemical compound O=C=NCCCCCCN=C=O RRAMGCGOFNQTLD-UHFFFAOYSA-N 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 238000010191 image analysis Methods 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 239000003112 inhibitor Substances 0.000 description 1
- 229910052809 inorganic oxide Inorganic materials 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- XJRAOMZCVTUHFI-UHFFFAOYSA-N isocyanic acid;methane Chemical compound C.N=C=O.N=C=O XJRAOMZCVTUHFI-UHFFFAOYSA-N 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 239000003350 kerosene Substances 0.000 description 1
- 150000002576 ketones Chemical class 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 239000003915 liquefied petroleum gas Substances 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- DAZXVJBJRMWXJP-UHFFFAOYSA-N n,n-dimethylethylamine Chemical compound CCN(C)C DAZXVJBJRMWXJP-UHFFFAOYSA-N 0.000 description 1
- ZUHZZVMEUAUWHY-UHFFFAOYSA-N n,n-dimethylpropan-1-amine Chemical compound CCCN(C)C ZUHZZVMEUAUWHY-UHFFFAOYSA-N 0.000 description 1
- VMOWKUTXPNPTEN-UHFFFAOYSA-N n,n-dimethylpropan-2-amine Chemical compound CC(C)N(C)C VMOWKUTXPNPTEN-UHFFFAOYSA-N 0.000 description 1
- IJDNQMDRQITEOD-UHFFFAOYSA-N n-butane Chemical compound CCCC IJDNQMDRQITEOD-UHFFFAOYSA-N 0.000 description 1
- OFBQJSOFQDEBGM-UHFFFAOYSA-N n-pentane Natural products CCCCC OFBQJSOFQDEBGM-UHFFFAOYSA-N 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000010680 novolac-type phenolic resin Substances 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 235000019198 oils Nutrition 0.000 description 1
- 239000007800 oxidant agent Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 150000002989 phenols Chemical class 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920005906 polyester polyol Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- WQGWDDDVZFFDIG-UHFFFAOYSA-N pyrogallyl group Chemical group C1(=C(C(=CC=C1)O)O)O WQGWDDDVZFFDIG-UHFFFAOYSA-N 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 239000011134 resol-type phenolic resin Substances 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 238000005563 spheronization Methods 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 125000000547 substituted alkyl group Chemical group 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- UQMOLLPKNHFRAC-UHFFFAOYSA-N tetrabutyl silicate Chemical compound CCCCO[Si](OCCCC)(OCCCC)OCCCC UQMOLLPKNHFRAC-UHFFFAOYSA-N 0.000 description 1
- LFQCEHFDDXELDD-UHFFFAOYSA-N tetramethyl orthosilicate Chemical compound CO[Si](OC)(OC)OC LFQCEHFDDXELDD-UHFFFAOYSA-N 0.000 description 1
- ZQZCOBSUOFHDEE-UHFFFAOYSA-N tetrapropyl silicate Chemical compound CCCO[Si](OCCC)(OCCC)OCCC ZQZCOBSUOFHDEE-UHFFFAOYSA-N 0.000 description 1
- 238000000954 titration curve Methods 0.000 description 1
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 1
- 150000003672 ureas Chemical class 0.000 description 1
- 235000015112 vegetable and seed oil Nutrition 0.000 description 1
- 239000008158 vegetable oil Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Images
Description
本発明は、球状鋳物砂、これを用いた鋳型やその製造方法及びこの鋳型により得られた鋳物に関する。 The present invention relates to a spherical casting sand, a mold using the sand, a manufacturing method thereof, and a casting obtained by the mold.
鋳造用鋳型（鋳型アセンブリーの各種粒状骨材製部材を含む）を製造する方法の一つとして、珪砂などの粒状骨材に、ポリオール化合物とポリイソシアネート化合物を各々主成分とする有機溶剤溶液から成る粘結剤を混合し、得られた混合物を模型に充填し、第三級アミン類の触媒作用によるウレタン化反応により硬化させることによって所望の鋳型を得る、いわゆるコールドボックス法、あるいはウレタン自硬性造型法が広く知られ実施されている。これらの鋳型造型法は、いずれも室温での硬化が可能で、速硬性があり、しかも鋳造後、鋳型の崩壊に優れているので、鋳物からの分離が極めて容易であるなどの利点を備えていることから、省エネルギー、高生産性鋳型造型法として使用が拡大している。 As one method for producing casting molds (including various granular aggregate members of the mold assembly), granular aggregates such as silica sand are composed of organic solvent solutions each containing a polyol compound and a polyisocyanate compound as main components. A so-called cold box method, or urethane self-hardening molding, is obtained by mixing a binder, filling the resulting mixture into a model, and curing by a urethanization reaction catalyzed by tertiary amines. The law is widely known and implemented. All of these mold making methods can be cured at room temperature, are fast-curing, and are excellent in mold collapse after casting, so that they can be separated from the casting very easily. Therefore, its use is expanding as an energy-saving and high-productivity mold making method.
コールドボックス法やウレタン自硬性造型法におけるガス欠陥を防止するために、強度を上げるバインダーを用いて添加量を減らす方法や、種々添加剤を用いて、ガス欠陥を防止する方法が開示されている（特許文献１）。また、コールドボックス法においては、可使時間を延長する方法が開示されている（特許文献２）。 In order to prevent gas defects in the cold box method and urethane self-hardening molding method, a method of reducing the amount of addition using a binder that increases the strength and a method of preventing gas defects using various additives are disclosed. (Patent Document 1). In the cold box method, a method for extending the pot life is disclosed (Patent Document 2).
一方、流動性に優れ、高強度かつ表面が平滑な鋳型を製造できる鋳物砂として、特許文献３には、特定の球状鋳物砂が開示されている。
しかしながら、特に肉厚が薄い部分を持つ鋳型の場合、鋳物に鋳ぐるまれるため、ガスが外部に逃げることが出来ず、ガス欠陥が発生することが多かった。また、肉厚が薄い部分を持つ鋳型の場合、鋳込み後の破損（例えば中子折れ等）を防止するためにバインダー量を増やして鋳型強度を高めることが行われる。バインダーの増量はガス欠陥につながるため、ガス欠陥の問題は一層顕著となる。 However, in particular, in the case of a mold having a thin wall portion, since it is cast into a casting, gas cannot escape to the outside, and gas defects often occur. Further, in the case of a mold having a thin portion, the mold strength is increased by increasing the amount of binder in order to prevent breakage after casting (for example, core breakage). Since the increase in binder leads to gas defects, the problem of gas defects becomes even more pronounced.
また、コールドボックス法においては、フェノール樹脂成分とポリイソシアネート成分とを混合後、気体状のアミンを通気させることで鋳型を硬化させるが、アミンの通気前に、ウレタン化反応が徐々に進行して、硬化し始める恐れがある。従って、長時間サンドホッパー内に保存した鋳型組成物は、所望の鋳型強度が得られない場合があり、造型不良の発生や、サンドホッパー内の清掃が必要で、より可使時間の長い鋳型組成物が求められていた。 In the cold box method, after mixing the phenol resin component and the polyisocyanate component, the mold is cured by aeration of gaseous amine, but the urethanization reaction proceeds gradually before the amine is aerated. , May start to cure. Therefore, the mold composition stored in the sand hopper for a long time may not be able to obtain the desired mold strength, which may cause molding defects and requires cleaning in the sand hopper. Things were sought.
本発明は、コールドボックス法やウレタン自硬性造型法のようにウレタンバインダーを用いて鋳型を製造する際に、ガス欠陥が少なく、より高強度で変形や破損が無く、また表面平滑性も良好な鋳型を製造できる鋳物砂を提供することを課題とする。更にコールドボックス法においては、より可使時間の長い鋳物砂を提供することを課題とする。 When producing a mold using a urethane binder such as the cold box method or urethane self-hardening molding method, the present invention has less gas defects, higher strength, no deformation or breakage, and good surface smoothness. It is an object to provide foundry sand capable of producing a mold. Furthermore, in the cold box method, it is an object to provide foundry sand having a longer pot life.
本発明は、平均粒径が０．０３〜１．５ｍｍである火炎溶融法にて製造された球状鋳物砂であって、ウレタンバインダーと共に用いられる球状鋳物砂に関する。 The present invention relates to a spherical foundry sand produced by a flame melting method having an average particle size of 0.03 to 1.5 mm, which is used together with a urethane binder.
また、本発明は、平均粒径が０．０３〜１．５ｍｍ、吸水率が０．５重量％以下の球状鋳物砂であって、ウレタンバインダーと共に用いられる球状鋳物砂に関する。 The present invention also relates to spherical foundry sand having an average particle size of 0.03 to 1.5 mm and a water absorption of 0.5% by weight or less, which is used together with a urethane binder.
また、本発明は、上記本発明の球状鋳物砂とウレタンバインダーとを混合する工程を有する鋳型の製造法に関する。 Moreover, this invention relates to the manufacturing method of the casting_mold | template which has the process of mixing the spherical foundry sand and urethane binder of the said invention.
また、本発明は、上記本発明の球状鋳物砂とウレタンバインダーとを含有する鋳型、及び該鋳型より得られた鋳物に関する。
Moreover, this invention relates to the casting containing the spherical casting sand of the said this invention and a urethane binder, and the casting obtained from this casting_mold | template.
本発明によれば、ウレタンバインダーを用いた鋳造法の課題であるガス発生量を大幅に減らすことが出来、ガス欠陥の少ない鋳物を得ることが出来る。 According to the present invention, it is possible to greatly reduce the amount of gas generated, which is a problem of a casting method using a urethane binder, and it is possible to obtain a casting with few gas defects.
また、薄肉部分を有する中子を作成する場合には、砂がよく充填された強度の高い中子を作ることが出来、これまでに無い複雑な形状の鋳物を製造することが出来る。 Moreover, when producing a core having a thin portion, a high-strength core that is well filled with sand can be produced, and a casting having a complicated shape that has never been produced can be produced.
更に、ポリオール成分とイソシアネート成分を混合後の可使時間が長く、造型不良の低減や鋳型の生産性を高めることが出来る。 Furthermore, the pot life after mixing the polyol component and the isocyanate component is long, so that molding defects can be reduced and the productivity of the mold can be increased.
これにより、その鋳物を用いた部品の軽量化、高強度化、他の部品との一体化、放冷性などの価値を付与することが出来る。 Thereby, value, such as weight reduction of components using the casting, high intensity | strength, integration with other components, and coolability, can be provided.
本発明で用いられる球状鋳物砂は大きく２つの態様からなり、中子用として特に好適である。第１の態様は、平均粒径が０．０３〜１．５ｍｍである、火炎熔融法で製造された球状鋳物砂である。また、第２の態様は、平均粒径が０．０３〜１．５ｍｍ、吸水率が０．５重量％以下である球状鋳物砂である。以下、これら２つを総称して「球状鋳物砂」ということがある。 The spheroidal sand used in the present invention is roughly composed of two embodiments and is particularly suitable for cores. A 1st aspect is the spherical foundry sand manufactured by the flame fusion method whose average particle diameter is 0.03-1.5 mm. Moreover, a 2nd aspect is spherical foundry sand whose average particle diameter is 0.03-1.5 mm, and a water absorption is 0.5 weight% or less. Hereinafter, these two may be collectively referred to as “spherical casting sand”.
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。本発明の効果を発現する観点から、球形度が０．９５以上の鋳物砂が好ましい。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. From the viewpoint of expressing the effect of the present invention, foundry sand having a sphericity of 0.95 or more is preferable. Whether or not it is spherical can be determined by observing the foundry sand with an optical microscope, a digital scope (for example, VH-8000, manufactured by Keyence Corporation) or the like, 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 the total components of the 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 resistance improvement of a spherical casting sand.
可使時間の短縮を防ぐ観点から、本発明の鋳物砂の酸消費量（ｍｌ／５０ｇ）の範囲としては、好ましくは１０（ｍｌ／５０ｇ）以下、より好ましくは５（ｍｌ／５０ｇ）以下である。尚、酸消費量の測定方法は、ＪＡＣＴ試験法Ｓ−4に記載された方法で乾燥砂５０ｇを０．１ｍｏｌ／Ｌ塩酸水溶液で攪拌した後、砂を除去し、反応液を０．１ｍｏｌ／Ｌ水酸化ナトリウム水溶液でｐＨ７まで逆滴定した値である。
From the viewpoint of preventing shortening of the pot life, the acid consumption (ml / 50 g) of the foundry sand of the present invention is preferably 10 (ml / 50 g) or less, more preferably 5 (ml / 50 g) or less. is there. The acid consumption was measured by the method described in JACT Test Method S-4, after stirring 50 g of dry sand with a 0.1 mol / L aqueous hydrochloric acid solution, the sand was removed, and the reaction solution was 0.1 mol / L. This is a value obtained by back titrating to pH 7 with an aqueous sodium hydroxide solution.
また更に同様に可使時間の短縮を防ぐ観点から、本発明の鋳物砂は、該鋳物砂１ｇ当りの溶出アルカリ量が１μｍｏｌ／ｇ以下、更に０．８μｍｏｌ／ｇ以下であることが好ましい。 Further, similarly, from the viewpoint of preventing shortening of the pot life, the casting sand of the present invention preferably has an elution alkali amount of 1 μmol / g or less, more preferably 0.8 μmol / g or less per 1 g of the casting sand.
溶出アルカリ量とは、鋳物砂から水抽出された強アルカリ成分の量であり、以下の通りに測定される。鋳物砂５０ｇに水５０ｍｌを加え１５分間攪拌し、１５分間静置した後、デカンテーションして得られた水層を溶出液とする。溶出液を２５ｍｌ採取し、ｐＨを測定しながら、０．１ｍｏｌ／Ｌ塩酸水溶液にて中和滴定を行い滴定曲線を得た後、変曲点を中和点とし滴定量（ｍｌ）とその時のｐＨを読み取る。 The elution alkali amount is the amount of a strong alkali component extracted from casting sand with water, and is measured as follows. 50 ml of water is added to 50 g of foundry sand, stirred for 15 minutes, allowed to stand for 15 minutes, and then the aqueous layer obtained by decantation is used as the eluent. 25 ml of the eluate was collected and neutralized titration was performed with 0.1 mol / L hydrochloric acid aqueous solution while measuring pH to obtain a titration curve. Read the pH.
中和点のうちｐＨが７以上、即ちアルカリ領域での中和点での滴定量から、下記式により、溶出アルカリ量を求める。ｐＨ７以上の中和点が二点以上ある場合はｐＨ７以上で最もｐＨが低い中和点を選択し、ｐＨ７以上の中和点がない場合は、０（μｍｏｌ／ｇ）とする。
溶出アルカリ量（μｍｏｌ／ｇ）＝
中和点における滴定量（ｍｌ）×０．１×５０／２５／５０×１０００
From the titration amount at the neutralization point where the pH is 7 or more, that is, the neutralization point in the alkaline region, the amount of eluted alkali is determined by the following formula. When there are two or more neutralization points at pH 7 or higher, the lowest neutralization point at pH 7 or higher is selected, and when there is no neutralization point at pH 7 or higher, 0 (μmol / g) is set.
Elution alkali amount (μmol / g) =
Titration volume at neutralization point (ml) x 0.1 x 50/25/50 x 1000
前記の酸消費量は鋳物砂中の溶出アルカリ分と共に、酸が砂表面と反応した量も含めた値となる。特に、火炎溶融法にて製造された砂においては、砂表面の官能基が多いと推察され、酸消費量が高くても可使時間が長い例があった。そこで、可使時間に大きく影響を及ぼす溶出アルカリ量を測定することが好ましい。特に、溶出アルカリ成分の中ではＣａ分の影響が大きく、これを低減することが好ましい。 The acid consumption amount is a value including the amount of the acid reacted with the sand surface together with the eluted alkali content in the foundry sand. In particular, sand produced by the flame melting method is presumed to have a large number of functional groups on the sand surface, and there have been examples in which the pot life is long even if the acid consumption is high. Therefore, it is preferable to measure the amount of eluted alkali that greatly affects the pot life. In particular, among the eluted alkaline components, the influence of Ca is large, and it is preferable to reduce this.
上記酸消費量、溶出アルカリ量を少なくする観点から、鋳物砂組成中のＮａ2Ｏ、Ｋ2Ｏの含有量としては、それぞれ好ましくは０．８重量％以下、より好ましくは０．５重量％以下、更に好ましくは０．３重量％以下である。また、ＣａＯの含有量としては、好ましくは１重量％以下、より好ましくは０．５重量％以下である。鋳物砂中の主成分がＳｉＯ2及び／又はＡｌ2Ｏ3である場合、ＭｇＯの含有量としては、好ましくは１重量％以下、より好ましくは０．５重量％以下である。これらの含有量にすることで、酸消費量及び溶出アルカリ量を下げ、可使時間の短縮を防ぐことが出来る。 From the viewpoint of reducing the amount of acid consumption and the amount of alkali eluted, the content of Na 2 O and K 2 O in the molding sand composition is preferably 0.8% by weight or less, more preferably 0.5% by weight, respectively. Hereinafter, it is further preferably 0.3% by weight or less. Further, the content of CaO is preferably 1% by weight or less, more preferably 0.5% by weight or less. When the main component in the foundry sand is SiO 2 and / or Al 2 O 3 , the MgO content is preferably 1% by weight or less, more preferably 0.5% by weight or less. By using these contents, the acid consumption amount and the eluted alkali amount can be reduced, and the pot life can be prevented from being shortened.
また、本発明の球状鋳物砂の熱膨張率は０．２％以下が好ましい。ウレタンバインダーは、硬化時に加熱する必要が無いため、より寸法精度の鋳型、特に中子を製造できるが、更にこのような熱膨張率の鋳物砂の使用により、鋳造時の寸法精度も向上させられるため好ましい。球状鋳物砂の熱膨張率は、鋳物砂の組成、結晶構造、非晶質成分の割合、等を調整することにより制御できる。 Further, the thermal expansion coefficient of the spherical casting sand of the present invention is preferably 0.2% or less. The urethane binder does not need to be heated at the time of curing, so it can produce more dimensional accuracy molds, especially cores. However, the use of casting sand with such a thermal expansion coefficient can also improve dimensional accuracy during casting. Therefore, it is preferable. The thermal expansion coefficient of the spherical casting sand can be controlled by adjusting the composition of the casting sand, the crystal structure, the ratio of the amorphous component, and the like.
尚、ここで、鋳物砂の熱膨張率は、ＪＡＣＴ試験法Ｍ-２に従って測定した１０００℃における急熱膨張の最大値を熱膨張率とする。 Here, regarding the thermal expansion coefficient of the foundry sand, the maximum value of rapid thermal expansion at 1000 ° C. measured according to the JACT test method M-2 is defined as the thermal expansion coefficient.
本発明の球状鋳物砂の平均粒径（ｍｍ）は０．０３〜１．５ｍｍの範囲であることが好ましい。０．０３ｍｍ以上であれば、鋳型の製造に多くのバインダーを必要とせず、鋳物砂として再生するのが容易となるため好ましい。１．５ｍｍ以下であれば、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く、また、火炎溶融法により球状鋳物砂を製造する場合、高い球形度の鋳物砂を得る観点から好ましい。球状鋳物砂の再生効率を高める観点から、０．０７〜１ｍｍが好ましく、０．０７〜０．５ｍｍがより好ましく、０．０７〜０．３５ｍｍが更に好ましい。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が更に好ましい。 The average particle size (mm) of the spherical casting sand of the present invention is preferably in the range of 0.03 to 1.5 mm. If it is 0.03 mm or more, a large amount of binder is not required for the production of the mold, and it is easy to regenerate as foundry sand, which is preferable. If it is 1.5 mm or less, it is preferable because the porosity is reduced and the strength of the mold is improved, and when spherical casting sand is produced by the flame melting method, it is preferable from the viewpoint of obtaining casting sand with high sphericity. From the viewpoint of increasing the recycling efficiency of the spherical casting sand, 0.07 to 1 mm is preferable, 0.07 to 0.5 mm is more preferable, and 0.07 to 0.35 mm is still more preferable. On the other hand, 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 even more preferable.
また、ガス硬化法であるいわゆるコールドボックス法では、３級アミンの通気により硬化反応がおきるため、通気性の観点から、本発明の球状鋳物砂の平均粒径は０．１ｍｍ〜１．５ｍｍが好ましい。通気性と鋳型強度の両者を高める観点からは、０．１ｍｍ〜０．５ｍｍが好ましく、より好ましくは０．１ｍｍ〜０．３ｍｍが好ましい。 In addition, in the so-called cold box method, which is a gas curing method, a curing reaction occurs due to the passage of tertiary amine. From the viewpoint of breathability, the average particle size of the spherical molding sand of the present invention is 0.1 mm to 1.5 mm. preferable. From the viewpoint of improving both air permeability and mold strength, the thickness is preferably 0.1 mm to 0.5 mm, more preferably 0.1 mm to 0.3 mm.
本発明の鋳物砂は、従来公知の鋳物砂と比較して、可使時間の延長効果がある。即ち、通常の鋳物砂においては、鋳物砂とポリオール成分、イソシアネート成分を混練後、放置した後ガッシングを行うと強度低下が見られるが、本発明の鋳物砂を用いるとその強度低下の割合が小さく、場合によっては強度上昇する。 The foundry sand of the present invention has an effect of extending the pot life as compared with conventionally known foundry sand. That is, in ordinary foundry sand, after casting sand, a polyol component, and an isocyanate component are kneaded and left standing and then gashed, a decrease in strength is observed. However, when the foundry sand of the present invention is used, the rate of decrease in strength is small. In some cases, the strength increases.
また、本発明の球状鋳物砂を用いた鋳型、特に中子は、鋳物砂が球形であるため、充填性が良好で、鋳型の表面を平滑に出来、鋳物の表面を平滑にすることが出来る。その観点から、平均粒径は０．０３〜１ｍｍが好ましく、０．０３〜０．３５ｍｍがより好ましく、０．０３〜０．１５ｍｍが更に好ましく、０．０３〜０．１ｍｍが特に好ましい。 In addition, the mold using the spherical foundry sand of the present invention, especially the core, has a good filling property because the foundry sand is spherical, the mold surface can be smoothed, and the casting surface can be smoothed. . From this viewpoint, the average particle size is preferably 0.03 to 1 mm, more preferably 0.03 to 0.35 mm, still more preferably 0.03 to 0.15 mm, and particularly preferably 0.03 to 0.1 mm.
本発明において、球状鋳物砂の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。 In the present invention, the average particle size of the spherical casting sand 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、光学顕微鏡又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及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 obtain 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、流動性の向上の観点、鋳型表面の平滑性の観点から、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以上であるものが更に好ましい。 The spherical casting sand of the present invention preferably has a sphericity of 0.95 or more, more preferably 0.98 or more from the viewpoint of improving fluidity and smoothness of the mold surface. And more preferably 0.99 or more.
また、本発明の第１の態様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、１重量％以下が好ましく、０．５重量％以下、０．３重量％以下がより好ましく、０．２重量％以下がさらに好ましく、０．１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。また、粘結剤で被覆されたＲＣＳや、鋳込み後の粘結剤残分が残留している場合は、熱処理（例えば１０００℃以上）等、適切な方法によって、それら成分を取り除いた後に吸水率を測定する。 Further, the water absorption rate (% by weight) of the spherical casting sand according to the first aspect of the present invention includes suppression of 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, From the viewpoint of improving the strength, etc., 1% by weight or less is preferable, 0.5% by weight or less, 0.3% by weight or less is more preferable, 0.2% by weight or less is more preferable, and 0.1% by weight or less is particularly preferable. preferable. The water absorption can be measured according to the method for measuring the water absorption of JIS A1109 fine aggregate. In addition, when the RCS coated with the binder or the binder residue after casting remains, the water absorption rate after removing these components by an appropriate method such as heat treatment (for example, 1000 ° C. or more). Measure.
一方、本発明の第２の態様の球状鋳物砂の吸水率は０．５重量％以下である。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、０．３重量％以下が好ましく、０．２重量％以下がより好ましく、０．１重量％以下がさらに好ましい。 On the other hand, the water absorption of the spherical casting sand of the second aspect of the present invention is 0.5% by weight or less. From the viewpoints of suppressing the increase in the amount of resin used due to absorption of the resin used in the production of the mold into the foundry sand and improving the mold strength, it is preferably 0.3% by weight or less, and 0.2% by weight or less. Is more preferable, and 0.1% by weight or less is more preferable.
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.
また、可使時間向上の観点からも、球形度は０．９５以上が好ましく、０．９７以上がより好ましく、０．９８以上がさらに好ましく、０．９９以上が特に好ましい。吸水率は、１重量％以下が好ましく、０．５重量％以下、０．３重量％以下がより好ましく、０．２重量％以下がさらに好ましく、０．１重量％以下が特に好ましい。 Further, from the viewpoint of improving the pot life, the sphericity is preferably 0.95 or more, more preferably 0.97 or more, further preferably 0.98 or more, and particularly preferably 0.99 or more. The water absorption is preferably 1% by weight or less, more preferably 0.5% by weight or less and 0.3% by weight or less, further preferably 0.2% by weight or less, and particularly preferably 0.1% by weight or less.
本発明の球状鋳物砂をウレタンバインダーに用いることにより、ウレタンバインダー特有の課題である可使時間延長効果がある理由の詳細は現在のところ不明であるが以下のように推察される。 Although the details of the reason for the effect of extending the pot life, which is a problem specific to the urethane binder, are not clear at present by using the spherical casting sand of the present invention for the urethane binder, it is presumed as follows.
ウレタンバインダーにおいては、前述の通り、フェノール樹脂成分とポリイソシアネート成分とを混合後、気体状のアミンを通気させることで鋳型を硬化させるが、アミンの通気前に、ウレタン化反応が徐々に進行して、硬化し始める恐れがある。 In the urethane binder, as described above, after mixing the phenol resin component and the polyisocyanate component, the mold is cured by passing a gaseous amine, but the urethane reaction proceeds gradually before the amine is passed. May start to harden.
特に、ポリイソシアネート成分は反応活性が高く、ウレタン化反応以外に空気中の水分とも反応する。また、砂表面の不純物等でイソシアネートの反応が促進される可能性も考えられる。 In particular, the polyisocyanate component has high reaction activity and reacts with moisture in the air in addition to the urethanization reaction. In addition, there is a possibility that the isocyanate reaction is accelerated by impurities on the sand surface.
本発明の球状鋳物砂は、吸水率が低いこと、あるいは火炎溶融法により製造されているため球形度が高いことから、鋳物砂の表面積が小さいためバインダーと鋳物砂表面、特に不純物との接触が相対的に少ないこと、また、同一添加量の場合、バインダーの膜厚が厚くなり、相対的に空気中の水分と接触する割合が少なくなっていることが関与して、ウレタンバインダー特有の成分であるイソシアネートがアミン通気前に反応するのを抑制していると推察される。 Since the spherical casting sand of the present invention has a low water absorption rate or is produced by the flame melting method and has a high sphericity, the surface area of the casting sand is small, so that the contact between the binder and the casting sand surface, particularly impurities, is low. In the case of relatively small amount, and in the case of the same addition amount, the thickness of the binder is increased, and the ratio of contact with moisture in the air is relatively small. It is presumed that a certain isocyanate suppresses reaction before amine aeration.
また、従来公知の鋳物砂と比べ、低添加量でバインダーの膜厚を厚くすることが出来るため、ガス欠陥を発生すること無しに上記効果を得ることが出来ると推察される。 Moreover, since the film thickness of a binder can be thickened with a low addition amount as compared with conventionally known foundry sand, it is presumed that the above-described effect can be obtained without causing gas defects.
本発明の球状鋳物砂は、中子等の鋳型の製造にあたり、単独で、若しくは珪砂等の従来公知の鋳物砂や耐火性骨材、更には従来公知の添加剤等を適宜混合して使用する。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好ましくは５０重量％以上、より好ましくは８０重量％以上含まれると、その効果は顕著になる。 The spherical casting sand of the present invention is used alone or in combination with a conventionally known casting sand such as silica sand, fireproof aggregate, and a conventionally known additive as appropriate in the production of a mold such as a core. . 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 in the foundry sand composed of the above mixture. If the spherical sand of the present invention having the predetermined sphericity is contained in an amount of preferably 50% by weight or more, more preferably 80% by weight or more, the effect becomes remarkable.
尚、前記混合物からなる鋳物砂には、０．０１ｍｍ以下の微粉が含まれていてもよいが、強度向上の観点から０．０１ｍｍ以下の微粉は前記混合物からなる鋳物砂中０．１重量％以下が好ましく、０．０５重量％以下がより好ましい。 In addition, although the fine sand of 0.01 mm or less may be contained in the foundry sand made of the mixture, the fine powder of 0.01 mm or less is 0.1% by weight in the foundry sand made of the mixture from the viewpoint of improving the strength. The following is preferable, and 0.05% by weight or less is more preferable.
前記の通り、本発明の第１の態様の球状鋳物砂は火炎溶融法により製造される。一方、本発明の第２の態様の球状鋳物砂は、たとえば、造粒して焼結する方法、電融アトマイズ法等の公知の方法により製造することが可能であるが、中でも、本発明の第１の態様の球状鋳物砂と同様に火炎溶融法により製造するのが好適である。火炎溶融法による、本発明の球状鋳物砂の製造方法としては、特開２００４-２０２５７７号に示されるような火炎溶融法が挙げられる。 As described above, the spherical foundry sand according to the first aspect of the present invention is manufactured by the flame melting method. On the other hand, the spherical foundry sand according to the second aspect of the present invention can be produced by a known method such as a method of granulating and sintering, an electromelting atomizing method, etc. It is preferable to manufacture by the flame melting method similarly to the spherical casting sand of the first aspect. Examples of the method for producing the spherical casting sand of the present invention by the flame melting method include a flame melting method as disclosed in JP-A No. 2004-202577.
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。 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.
また、可使時間向上の観点から、火炎溶融法による処理前、及び/又は処理後に、洗浄・乾燥することが好ましい。洗浄には、水のほか、酸・アルカリ水溶液、各種活性剤溶液等が用いることが出来る。 From the viewpoint of improving the pot life, it is preferable to wash and dry before and / or after the treatment by the flame melting method. In addition to water, acid / alkaline aqueous solutions, various activator solutions, and the like can be used for washing.
本発明の球状鋳物砂は、ウレタンバインダーと共に用いられる。ウレタンバインダーとは、ポリオール化合物（特にフェノール樹脂）とポリイソシアネート化合物を粘結剤として用い、それらの重付加反応を利用して鋳型を硬化させるバインダーである。 The spheroidal sand of the present invention is used together with a urethane binder. A urethane binder is a binder that uses a polyol compound (particularly a phenol resin) and a polyisocyanate compound as a binder and cures a mold by using a polyaddition reaction thereof.
ウレタンバインダーにおけるポリオール化合物としては、従来公知のフェノール樹脂、脂肪族ポリオールが挙げられ、特に限定されるものではない。具体的には、フェノール類とアルデヒド類（好ましくは、ホルムアルデヒド）とを付加・縮合反応せしめることにより得られる、溶剤に可溶なベンジルエーテル型フェノール樹脂、レゾール型フェノール樹脂、ノボラック型フェノール樹脂、オルソクレゾール変性フェノール樹脂及びこれらの変性フェノール樹脂、並びにこれらの混合物が挙げられる。 Examples of the polyol compound in the urethane binder include conventionally known phenol resins and aliphatic polyols, and are not particularly limited. Specifically, benzyl ether type phenolic resin, resol type phenolic resin, novolac type phenolic resin, orthosolic acid obtained by addition / condensation reaction of phenols and aldehydes (preferably formaldehyde) are used. Examples include cresol-modified phenolic resins and these modified phenolic resins, and mixtures thereof.
これらの、フェノール樹脂は、低粘度化、後述するポリイソシアネート成分との相溶性、鋳物砂へのコーティング性、鋳型物性等の観点から、一般に、溶剤に溶解せしめられ、その濃度が、約３０〜８０重量％程度とされた溶液の状態で、用いることが好ましい。 These phenolic resins are generally dissolved in a solvent from the viewpoints of viscosity reduction, compatibility with the polyisocyanate component described later, coating properties on molding sand, physical properties of the mold, etc. It is preferably used in the state of a solution of about 80% by weight.
ウレタンバインダーにおけるポリイソシアネート化合物としては、上記のポリオール化合物の活性水素と重付加反応することにより鋳物砂間に化学的な結合を形成せしめ得る、イソシアネート基を、分子内に２以上有する化合物であり、その具体例としては、芳香族、脂肪族或いは脂環式のポリイソシアネート、例えば、ジフェニルメタンジイソシアネート、ポリメチレンポリフェニレンポリイソシアネート（以下、ポリメリックＭＤＩと呼称する。）、ヘキサメチレンジイソシアネート、４，４’-ジシクロヘキシルメタンジイソシアネートの他、これらポリイソシアネート化合物をポリエーテルポリオール、ポリエステルポリオール等のポリオールと反応させて得られるイソシアネート基を２以上有するプレポリマー等、従来より公知の各種のポリイソシアネートを挙げることが出来、これらは、単独で用いても、或いは、２種以上を組み合わせて用いてもよい。 The polyisocyanate compound in the urethane binder is a compound having two or more isocyanate groups in the molecule, which can form a chemical bond between the foundry sand by polyaddition reaction with the active hydrogen of the above polyol compound, Specific examples thereof include aromatic, aliphatic or alicyclic polyisocyanates such as diphenylmethane diisocyanate, polymethylene polyphenylene polyisocyanate (hereinafter referred to as polymeric MDI), hexamethylene diisocyanate, 4,4′-dicyclohexyl. In addition to methane diisocyanate, each conventionally known prepolymer having two or more isocyanate groups obtained by reacting these polyisocyanate compounds with polyols such as polyether polyol and polyester polyol, etc. The polyisocyanate of a seed | species can be mentioned, These may be used independently or may be used in combination of 2 or more type.
これらのポリイソシアネート化合物においても、上記のポリオール化合物と同様の理由から、溶剤を溶媒として用い、この有機溶媒に、濃度が、約４０〜９０重量％程度となるように溶解された溶液として用いることが好ましい。 In these polyisocyanate compounds, for the same reason as the above polyol compound, a solvent is used as a solvent, and a solution dissolved in this organic solvent so as to have a concentration of about 40 to 90% by weight is used. Is preferred.
上記のポリオール化合物及びポリイソシアネート化合物に用いられる溶剤としては、ポリイソシアネート化合物には非反応性で、且つ溶解対象である溶質（フェノール樹脂又はポリイソシアネート）に対して良溶媒であれば、特に制限されず有機溶剤、無機系溶剤など従来公知の溶剤を用いることが出来る。 The solvent used in the above polyol compound and polyisocyanate compound is not particularly limited as long as it is non-reactive with the polyisocyanate compound and is a good solvent for the solute (phenol resin or polyisocyanate) to be dissolved. Conventionally known solvents such as organic solvents and inorganic solvents can be used.
有機溶剤においては、一般に、フェノール樹脂を溶解するための極性溶剤と、フェノール樹脂の分離が生じない程度の量のポリイソシアネート化合物を溶解するための非極性溶剤とが組み合わされて用いるのが好ましい。 In general, it is preferable to use a combination of a polar solvent for dissolving the phenol resin and a nonpolar solvent for dissolving the polyisocyanate compound in such an amount that does not cause separation of the phenol resin.
フェノール樹脂を溶解するための極性溶剤としては、ジカルボン酸メチルエステル混合物（デュポン社製；商品名：ＤＢＥ；グルタル酸ジメチルとアジピン酸ジメチルとコハク酸ジメチルとの混合物）等のジカルボン酸アルキルエステル、菜種油メチルエステル等の植物油のメチルエステル、オレイン酸エチル、パルミチン酸エチル、これらの混合物等の脂肪酸モノエステル等のエステル類の他、例えば、イソホロン等のケトン類、イソプロピルエーテル等のエーテル類、フルフリルアルコール等が挙げられる。 Examples of polar solvents for dissolving the phenolic resin include dicarboxylic acid methyl ester mixtures (manufactured by DuPont; trade name: DBE; a mixture of dimethyl glutarate, dimethyl adipate and dimethyl succinate), and rapeseed oil. In addition to esters such as methyl esters of vegetable oils such as methyl esters, fatty acid monoesters such as ethyl oleate and ethyl palmitate, and mixtures thereof, for example, ketones such as isophorone, ethers such as isopropyl ether, and furfuryl alcohol Etc.
フェノール樹脂の分離が生じない程度の量のポリイソシアネート化合物を溶解するための非極性溶剤としては、例えば、パラフィン類、ナフテン類、アルキルベンゼン類等の石油系炭化水素類、具体例としては、イプゾール１５０（出光石油社製；石油系溶剤）、ハイゾール（昭和シェル石油社製；石油系溶剤）等を例示することが出来る。 Examples of the nonpolar solvent for dissolving the polyisocyanate compound in such an amount that does not cause separation of the phenol resin include petroleum hydrocarbons such as paraffins, naphthenes, alkylbenzenes, and specific examples include Ipsol 150. (Idemitsu Oil Co., Ltd .; petroleum solvent), Hysol (Showa Shell Sekiyu Co., Ltd .; petroleum solvent) and the like can be exemplified.
無機系溶剤においては、アルキルケイ酸エステル及びその加水分解物が挙げられ、例えばメチルシリケート、エチルシリケート、プロピルシリケート、ブチルシリケートなど、ケイ酸エステルの加水分解生成物、などが挙げられる。これらは、強度向上、ガス発生低減、崩壊性向上などの観点から、単独で若しくは有機溶剤と併用して用いられる。 Examples of the inorganic solvent include alkyl silicate esters and hydrolysates thereof, and examples thereof include hydrolysis products of silicate esters such as methyl silicate, ethyl silicate, propyl silicate, and butyl silicate. These are used alone or in combination with an organic solvent from the viewpoints of strength improvement, gas generation reduction, and disintegration improvement.
ウレタンバインダーは、ポリオール化合物とポリイソシアネート化合物の重量比が、ポリオール化合物：ポリイソシアネート化合物＝１００：１１０〜１００：１６０の範囲で使用することが好ましく、ポリオール化合物：ポリイソシアネート化合物＝１００：１２０〜１００：１５５の範囲が更に好適である。 The urethane binder is preferably used so that the weight ratio of the polyol compound and the polyisocyanate compound is in the range of polyol compound: polyisocyanate compound = 100: 110 to 100: 160, and polyol compound: polyisocyanate compound = 100: 120 to 100 A range of 155 is more preferred.
ウレタンバインダーの主成分はポリオール化合物とポリイソシアネート化合物であり、溶剤を含む場合もある。ウレタンバインダーの使用量（溶剤を含む場合は、溶剤を含めた量とする）は、鋳型強度の点から、本発明の球状鋳物砂を含む鋳物砂１００重量部に対して０．３〜３重量部が好ましく、更に好ましくは０．３〜２．２重量部で、より好ましくは０．３〜１．７重量部である。 The main components of the urethane binder are a polyol compound and a polyisocyanate compound, and may contain a solvent. The amount of the urethane binder used (in the case of containing a solvent, the amount including the solvent) is 0.3 to 3 weights with respect to 100 parts by weight of the foundry sand containing the spherical foundry sand of the present invention in terms of mold strength. Parts, preferably 0.3 to 2.2 parts by weight, more preferably 0.3 to 1.7 parts by weight.
本発明で使用できるウレタンバインダーの硬化用触媒は、第三級アミン化合物が好適であり、例示すると、コールドボックス造型法においては、トリエチルアミン、ジメチルエチルアミン、ジメチルｎ-プロピルアミン、ジメチルイソプロピルアミン等の易気化性化合物をガス状、又はエアロゾル状としたものが、ウレタン自硬性造型法においては、４-フェニルプロピルピリジン、エチルモルホリン、Ｎ-メチルイミダゾール等をそのまま、もしくは有機溶剤により適宜希釈したものが好適に使用できる。又、かかるウレタン自硬性造型法用硬化触媒は、ウレタンバインダーのポリオール化合物成分に予め添加、混合しておくことも出来る。硬化用触媒の使用量は、コールドボックス造型法においても、ウレタン自硬性造型法においても、前記ポリオール化合物の使用量１００重量部に対して、０．１〜２０重量部が好ましい。 The urethane binder curing catalyst that can be used in the present invention is preferably a tertiary amine compound. For example, in the cold box molding method, triethylamine, dimethylethylamine, dimethyl n-propylamine, dimethylisopropylamine, etc. Vaporizable compounds in gaseous or aerosol form are suitable for urethane self-hardening molding methods, such as 4-phenylpropylpyridine, ethylmorpholine, N-methylimidazole, etc. as they are, or appropriately diluted with an organic solvent. Can be used for Moreover, the curing catalyst for urethane self-hardening molding method can be added and mixed in advance with the polyol compound component of the urethane binder. The amount of the curing catalyst used is preferably 0.1 to 20 parts by weight with respect to 100 parts by weight of the polyol compound used in both the cold box molding method and the urethane self-hardening molding method.
本発明の球状鋳物砂を用いた鋳造用鋳型の製造方法の一例として、本発明の球状鋳物砂に、ポリオール化合物を主成分とする有機溶剤溶液、及びポリイソシアネート化合物、又はポリイソシアネート化合物を主成分とする有機溶剤溶液とから成る粘結剤を添加し、攪拌混合し、得られた混合物を模型に充填し、次いで、該混合物を、ガス状、又はエアロゾル状第三級アミンを接触させることによって固化させる鋳造用鋳型の製造方法が挙げられる。 As an example of a method for producing a casting mold using the spherical molding sand of the present invention, an organic solvent solution containing a polyol compound as a main component and a polyisocyanate compound or a polyisocyanate compound as a main component in the spherical casting sand of the present invention. By adding a binder consisting of an organic solvent solution, stirring and mixing, filling the resulting mixture into a model, and then contacting the mixture with a gaseous or aerosol tertiary amine Examples include a method for producing a casting mold to be solidified.
また、本発明の球状鋳物砂を用いた鋳造用鋳型の製造方法の他の例として、本発明の球状鋳物砂に、ポリオール化合物を主成分とする有機溶剤溶液と、ポリイソシアネート化合物、又はポリイソシアネート化合物を主成分とする有機溶剤溶液とからなる粘結剤、及び硬化触媒として液体状の第三級アミンを添加し、攪拌混合し、得られた混合物を模型に充填し、固化させる鋳造用鋳型の製造方法が挙げられる。 In addition, as another example of a method for producing a casting mold using the spherical casting sand of the present invention, an organic solvent solution containing a polyol compound as a main component, a polyisocyanate compound, or a polyisocyanate is added to the spherical casting sand of the present invention. A casting mold for adding a binder composed of an organic solvent solution containing a compound as a main component and a liquid tertiary amine as a curing catalyst, stirring and mixing, filling the resulting mixture into a model, and solidifying the mixture. The manufacturing method of these is mentioned.
また、本発明の球状鋳物砂を用いた鋳型の製造においては、適宜従来公知の添加剤、即ちシランカップリング剤や、崩壊性向上剤、臭気低減剤、可使時間延長剤、しみ付き防止剤、強度向上剤等を使用できる。シランカップリング剤の量は、ウレタンバインダー１００重量部に対して０．０１〜１０重量部含有させるのが崩壊性の観点から好ましい。 Further, in the production of a mold using the spherical casting sand of the present invention, conventionally known additives as appropriate, that is, silane coupling agents, disintegration improvers, odor reducing agents, pot life extenders, anti-smudge agents. , Strength improvers and the like can be used. The amount of the silane coupling agent is preferably 0.01 to 10 parts by weight with respect to 100 parts by weight of the urethane binder from the viewpoint of disintegration.
崩壊性向上剤の例としては、珪酸エステル、シリカゾル、オルガノハロホスフェート、亜リン酸エステル、アルカリ金属酸素酸塩や、鉄、銅、ニッケル、コバルト及び亜鉛の群から選ばれる１種の金属元素を有する少なくとも１種の金属酸化物、等が挙げられる。 Examples of disintegration improvers include silicate esters, silica sols, organohalophosphates, phosphites, alkali metal oxyacid salts, and one metal element selected from the group of iron, copper, nickel, cobalt, and zinc. And at least one metal oxide.
臭気低減剤の例としては、フマル酸等のカルボン酸、アルカリ金属塩、アルカリ土類金属塩、無機酸化物等が挙げられる。 Examples of the odor reducing agent include carboxylic acids such as fumaric acid, alkali metal salts, alkaline earth metal salts, inorganic oxides, and the like.
可使時間延長剤、方法の例としては、イソフタル酸クロライド等の酸クロライド、亜リン酸エステル、２，２’‐ジピリジル、１，１０‐フェナントロリン及びそれらの置換アルキル誘導体、カテコールやピロガロール等の芳香族化合物、ホウ酸等のホウ素化合物、二価金属塩含有量が５０ppm以下のバインダー組成物を用いる方法、エポキシ樹脂とアクリル化有機ポリイソシアナート、反応性不飽和アクリル単量体、重合体、及びそれらの混合物、及びヒドロペルオキシドから成る酸化剤を組み合わせる方法が挙げられる。 Examples of pot life extenders and methods include acid chlorides such as isophthalic acid chloride, phosphites, 2,2'-dipyridyl, 1,10-phenanthroline and substituted alkyl derivatives thereof, fragrances such as catechol and pyrogallol Group compounds, boron compounds such as boric acid, a method using a binder composition having a divalent metal salt content of 50 ppm or less, an epoxy resin and an acrylated organic polyisocyanate, a reactive unsaturated acrylic monomer, a polymer, and A method of combining a mixture thereof and an oxidizing agent comprising hydroperoxide is mentioned.
しみ付き防止剤の例としては、脂肪族モノイソシアネート、ポリイソシアネートとポリエーテルポリオール等を反応させたウレタンプレポリマーや、ポリブタジエン及び、官能性ポリブタジエンやフェノール性水酸基を有する変性ポリブタジエン等が挙げられる。 Examples of the stain inhibitor include urethane prepolymers obtained by reacting aliphatic monoisocyanates, polyisocyanates and polyether polyols, polybutadienes, modified polybutadienes having functional polybutadienes or phenolic hydroxyl groups, and the like.
強度向上剤の例としては、酸アミド、尿素誘導体等が挙げられる。 Examples of strength improvers include acid amides and urea derivatives.
また、本発明の球状鋳物砂を用いた鋳型の製造においては、ウレタンバインダーの添加量を低減できる（即ち、ガス発生量を大幅に減らすことができる）ため、ウレタンバインダーの課題であるガス欠陥が大幅に削減されると共に、強度が高いため、複雑形状、特に薄肉部分を持つ中子等の鋳型を生産性高く製造できる。特に、肉厚が５ｍｍ以下、好ましくは４ｍｍ以下の薄肉部分を持つ鋳型、なかでも中子については、本発明の球状鋳物砂を用いることで、流動性が高く充填不良も防止できる。なお、ここで、５ｍｍ以下の薄肉部分を持つ鋳型とは、成形後の鋳型の最狭部分の厚みが５ｍｍ以下である鋳型を表す。 In addition, in the production of a mold using the spheroidal sand of the present invention, the amount of urethane binder added can be reduced (that is, the amount of gas generated can be greatly reduced). Since it is greatly reduced and the strength is high, a mold such as a core having a complicated shape, particularly a thin portion can be manufactured with high productivity. In particular, for a mold having a thin portion with a wall thickness of 5 mm or less, preferably 4 mm or less, especially a core, the use of the spherical casting sand of the present invention has high fluidity and can prevent poor filling. Here, the mold having a thin portion of 5 mm or less represents a mold in which the thickness of the narrowest portion of the molded mold is 5 mm or less.
また、本発明の球状鋳物砂は球形度が高く、充填性が高いため、鋳型の表面が平滑になり、得られる鋳物の表面即ち鋳肌の平滑な鋳物が得られる。 Further, since the spherical casting sand of the present invention has a high sphericity and a high filling property, the surface of the mold becomes smooth, and a casting having a smooth casting surface or casting surface can be obtained.
即ち、本発明の球状鋳物砂を用いて得られた中子等の鋳型を用い、複雑形状で、後加工できない部分の鋳肌を平滑にすることが出来るため、流体が通過するような複雑な穴を有する鋳物部材に有用で、鋳物表面の粗さによる抵抗を低減でき、本部材を取り扱う装置の省エネルギー化、小型化を達成することが可能となる。 In other words, using a mold such as a core obtained by using the spherical casting sand of the present invention, it is possible to smooth the casting surface of the part that cannot be post-processed with a complicated shape, so that the fluid passes through It is useful for a casting member having a hole, can reduce resistance due to the roughness of the casting surface, and can achieve energy saving and downsizing of an apparatus for handling this member.
本発明の球状鋳物砂とウレタンバインダーとを含有する鋳型は、表面粗さＲａが２０μｍ以下が好ましく、更に１〜１５μｍであることが好ましい。Ｒａは、後述の実施例のように、表面粗さ測定器により測定できる。 The mold containing the spherical foundry sand and the urethane binder of the present invention preferably has a surface roughness Ra of 20 μm or less, and more preferably 1 to 15 μm. Ra can be measured by a surface roughness measuring instrument as in the examples described later.
また、本発明の球状鋳物砂を用いた鋳型は、球状であるため鋳込み後には容易に崩壊し、複雑形状の鋳型でも容易に砂を除去できる。また、積層造型法や切削鋳型に用いると、未硬化部分、不要部分の砂が容易に除去できるため好適に使用できる。 Moreover, since the casting mold using the spherical casting sand of the present invention is spherical, it easily collapses after casting, and the sand can be easily removed even with a casting mold having a complicated shape. Moreover, when it uses for a lamination molding method or a cutting mold, since the sand of an unhardened part and an unnecessary part can be removed easily, it can be used conveniently.
本発明の球状鋳物砂は、造型後若しくは鋳込み後、ばらした砂を再利用することが出来る。その際には、従来公知の方法、焙焼処理や粒子間摩擦式などの機械的処理、水洗、酸洗、アルカリ洗浄、溶剤洗浄等の処理で再生処理を施すことが出来る。このような再生処理を行った鋳物砂、いわゆる再生砂を再度、本発明の鋳型造型に用いることも出来る。 The spheroidal sand of the present invention can be reused after being molded or after casting. At that time, the regeneration treatment can be performed by a conventionally known method, mechanical treatment such as roasting treatment or interparticle friction method, water washing, pickling, alkali washing, solvent washing and the like. Cast sand that has been subjected to such a regeneration treatment, so-called reclaimed sand, can be used again for the mold making of the present invention.
再生砂の場合の、球状鋳物砂の球形度及び吸水率の測定方法は、バインダー種に応じて適宜バインダー成分を取り除いた後、測定する。例えば、有機質バインダーの場合、１０００℃、１時間にて有機分を除去した後、球形度及び吸水率を測定する。無機質バインダーの場合は水洗、酸洗、アルカリ洗浄などの方法を取る。 In the case of reclaimed sand, the method for measuring the sphericity and water absorption of the spherical casting sand is carried out after appropriately removing the binder component according to the binder type. For example, in the case of an organic binder, the organic content is removed at 1000 ° C. for 1 hour, and then the sphericity and water absorption are measured. In the case of an inorganic binder, a method such as washing with water, pickling or alkali washing is used.
特に、本発明の球状鋳物砂を用いて得られた中子は、球形度が高い砂を用いているため、通気性が良く、消失模型鋳造法、フルモールド法、Ｖプロセス、吸引鋳造等、鋳型に通気性が要求される分野の鋳造方法にも好適に使用でき、更に、かかる中子はガス発生量を少なくすることができるため、特にガス欠陥やヤニ欠陥が生じやすい金型鋳造法、例えば低圧鋳造や高圧鋳造、ダイキャスト用の中子にも好適に使用できる。 In particular, since the core obtained using the spherical casting sand of the present invention uses sand having a high sphericity, the air permeability is good, the disappearance model casting method, the full mold method, the V process, the suction casting, etc. It can also be suitably used for casting methods in the field where air permeability is required for the mold, and since the core can reduce the amount of gas generated, a die casting method that is particularly prone to gas defects and spear defects, For example, it can be suitably used for a core for low pressure casting, high pressure casting or die casting.
本発明の中子は鋳物として最も複雑な構造を有し、かつ鋳肌表面の美しさ、寸法精度が要求されるものに使用できる。特に気体や液体などの流体が通過する面を有する部品や、これまでのいくつかの部品を組合せ一体化した部品に好適に用いられる。 The core of the present invention has the most complicated structure as a casting, and can be used for those requiring the beauty of the casting surface and dimensional accuracy. In particular, it is suitably used for a part having a surface through which a fluid such as gas or liquid passes, or a part obtained by combining and integrating several parts so far.
具体的には、水道や油圧のバルブや配管部品、フィン部分が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）、駆動伝達装置の部品、金型、工作機械部品、建築部材などが挙げられる。 Specifically, water and hydraulic valves and piping parts, motor parts (casing) with complex fins, pump parts (such as impellers) and engine parts (frames) that require smoothness, drive transmission parts, Examples include molds, machine tool parts, and building materials.
本発明の中子等の鋳型を用いることにより、表面粗さＲａが１０ｍｍ以下である鋳物を得ることが可能であり、鋳物の組成として、鋳鋼、鋳鉄、アルミニウム、銅、マグネシウムおよびこれらの合金等の鋳型用途に好適に使用される。本発明は、ウレタンバインダーの添加量を低減できるため、鋳型からのガス発生量が少なく出来ることから、ガス欠陥にシビアな銅、アルミ、マグネシウムなどに好適である。 By using a mold such as the core of the present invention, it is possible to obtain a casting having a surface roughness Ra of 10 mm or less. As the composition of the casting, cast steel, cast iron, aluminum, copper, magnesium, alloys thereof and the like It is suitably used for the mold application. The present invention is suitable for copper, aluminum, magnesium, etc., which are severe in gas defects, because the amount of urethane binder added can be reduced and the amount of gas generated from the mold can be reduced.
以下に、実施例及び比較例で用いた鋳物砂を示す。それぞれの組成及び物性を表１に示す。
＊球状鋳物砂（１）；
火炎溶融法により得られた、組成が、Ａｌ2Ｏ3：６３．８重量％、ＳｉＯ2：３０．２重量％、Ｆｅ2Ｏ3：１．３重量％、ＴｉＯ2：２．９重量％、ＣａＯ：０．3重量％、ＭｇＯ：０．1重量％、Ｎａ2Ｏ：０．１重量％、Ｋ2Ｏ：０．１重量％（組成はすべてJIS R 2212にて測定、以下同様）で、平均粒径が０．１５ｍｍ、球形度０．９８、吸水率０．０２重量％、酸消費量１．３ｍｌ／５０ｇの球状鋳物砂。
Below, the foundry sand used by the Example and the comparative example is shown. The respective compositions and physical properties are shown in Table 1.
* Spherical casting sand (1);
The composition obtained by the flame melting method was Al 2 O 3 : 63.8% by weight, SiO 2 : 30.2% by weight, Fe 2 O 3 : 1.3% by weight, TiO 2 : 2.9% by weight , CaO: 0.3% by weight, MgO: 0.1% by weight, Na 2 O: 0.1% by weight, K 2 O: 0.1% by weight (all compositions are measured according to JIS R 2212, the same applies hereinafter) Spherical foundry sand having an average particle size of 0.15 mm, a sphericity of 0.98, a water absorption of 0.02% by weight, and an acid consumption of 1.3 ml / 50 g.
＊球状鋳物砂（２）〜（５）；
球状鋳物砂（１）と組成及び物性が異なる、火炎溶融法により得られた球状鋳物砂。
* Spherical casting sand (2) to (5);
Spherical foundry sand obtained by the flame melting method, whose composition and physical properties are different from the spherical cast sand (1).
＊従来鋳物砂（１）；
造粒焼成法により得られたムライト砂であり、Ａｌ2Ｏ3／ＳｉＯ2重量比率が２．７となるよう水酸化アルミニウムとカオリンを混合し、スプレードライヤーを用いて平均粒径０．２ｍｍの球状にした粉末粒子（Ａｌ2Ｏ3とＳｉＯ2を合計量で９６重量％含有）を電気炉中にて１５００℃で１時間焼成することにより得た。Ａｌ2Ｏ3とＳｉＯ2の合計含有量は９７重量％、Ａｌ2Ｏ3／ＳｉＯ2重量比率は２．７、平均粒径は０．１８ｍｍ、球形度は０．８９、吸水率は１．２重量％、酸消費量１．６ｍｌ／５０ｇ、粒子密度は２．７ｇ／ｃｍ3であった。
* Conventional casting sand (1);
It is mullite sand obtained by the granulation firing method, and aluminum hydroxide and kaolin are mixed so that the Al 2 O 3 / SiO 2 weight ratio is 2.7, and the average particle size is 0.2 mm using a spray dryer. Spherical powder particles (containing 96% by weight of Al 2 O 3 and SiO 2 in total) were fired in an electric furnace at 1500 ° C. for 1 hour. The total content of Al 2 O 3 and SiO 2 is 97% by weight, the Al 2 O 3 / SiO 2 weight ratio is 2.7, the average particle size is 0.18 mm, the sphericity is 0.89, and the water absorption is 1. The amount of acid consumption was 1.6 ml / 50 g, and the particle density was 2.7 g / cm 3 .
＊従来鋳物砂（２）；珪砂（アルバニー７号）。平均粒径０．１８ｍｍ、球形度０．８８、吸水率０．８０重量％、酸消費量１．３ｍｌ／５０ｇ * Conventional casting sand (2); quartz sand (Albany No. 7). Average particle size 0.18mm, sphericity 0.88, water absorption 0.80% by weight, acid consumption 1.3ml / 50g
＜実施例１〜４及び比較例１〜３＞
表１に示す鋳物砂を表２のように用い、これと表２のウレタンバインダーを用いて鋳型用混練砂を調製し、以下の評価を行った。結果を表２に示す。
<Examples 1-4 and Comparative Examples 1-3>
The casting sand shown in Table 1 was used as shown in Table 2, and using this and the urethane binder shown in Table 2, the kneading sand for the mold was prepared, and the following evaluation was performed. The results are shown in Table 2.
＜評価＞
（１）抗折強度
表２に示す鋳物砂を１００重量部、ポリオール化合物の有機溶剤溶液〔商品名「ISOCURE パートＩ」、保土谷アシュランド（株）製〕を表２に示す量、及びポリイソシアネート化合物の有機溶剤溶液〔商品名「ISOCURE パートII」、保土谷アシュランド（株）製〕を表２に示す量、室温にてミキサーにて混合して鋳型用混練砂を調製した後、厚さ１０ｍｍ×幅３０ｍｍ×長さ８０ｍｍの型に充填し、トリエチルアミンをポリオール化合物有機溶剤溶液に対し５重量％注入、気化させ、４０秒間通気し硬化させ、抜型した。２４時間後に、曲げ強さ（抗折強度）を、島津製作所製 強度試験機ＡＧ-５０００Ｄで測定した。
<Evaluation>
(1) Folding strength 100 parts by weight of casting sand shown in Table 2, organic solvent solution of polyol compound [trade name "ISOCURE Part I", manufactured by Hodogaya Ashland Co., Ltd.] An organic solvent solution of an isocyanate compound [trade name “ISOCURE Part II”, manufactured by Hodogaya Ashland Co., Ltd.] was mixed in an amount shown in Table 2 with a mixer at room temperature to prepare kneaded sand for a mold. The mold was filled in a mold of 10 mm length × 30 mm width × 80 mm length, 5% by weight of triethylamine was injected into the polyol compound organic solvent solution, vaporized, cured by aeration for 40 seconds, and then removed. After 24 hours, the bending strength (bending strength) was measured with a strength tester AG-5000D manufactured by Shimadzu Corporation.
（２）鋳込み時の評価
上記（１）と同様に調製した鋳型用混練砂とトリエチルアミンを表２のように用いて図１の形状の中子を作成し、図２の形状の鋳物用の鋳型（主型）に設置して、鋳鉄溶湯（ＦＣ２５０）を鋳込み、ガス欠陥と鋳込み後の中子折れの有無を評価した。
(2) Evaluation at the time of casting The mold kneading sand and triethylamine prepared in the same manner as in the above (1) were used as shown in Table 2 to create the core shown in FIG. 1, and the casting mold having the shape shown in FIG. It was installed in (main mold), cast iron melt (FC250) was cast, and the presence of gas defects and core breakage after casting was evaluated.
得られた鋳物を、中心部を通るように縦方向に切断加工し、切断加工面のガス欠陥（ピンホール欠陥）の個数を、液体浸透探傷法（カラーチェック）により赤色斑点の個数として測定した。鋳込み後の中子折れは、切断加工面の中子部分の形状を観察し、折れ（変形した場合も含む）の有無を確認した。 The obtained casting was cut in the longitudinal direction so as to pass through the center portion, and the number of gas defects (pinhole defects) on the cut surface was measured as the number of red spots by the liquid penetration flaw detection method (color check). . For core breakage after casting, the shape of the core portion of the cut surface was observed and the presence or absence of breakage (including deformation) was confirmed.
なお、主型は、中子と同じ鋳型用混練砂を用い、ウレタンバインダーと同じ添加量のフェノールウレタンバインダーを用いた自硬性鋳型により作製した。このフェノールウレタンバインダーは、ポリオール化合物の有機溶剤溶液〔商品名「PEPSET パートR」、保土谷アシュランド（株）製〕、ポリイソシアネート化合物の有機溶剤溶液〔商品名「PEPSET パートM」、保土谷アシュランド（株）製〕及び硬化触媒〔商品名「PEPSET パートK」、保土谷アシュランド（株）製〕からなるものである。 The main mold was made of the same mold sand as the core and a self-hardening mold using the same amount of phenol urethane binder as the urethane binder. This phenol-urethane binder contains an organic solvent solution of a polyol compound (trade name “PEPSET Part R” manufactured by Hodogaya Ashland Co., Ltd.), an organic solvent solution of a polyisocyanate compound [trade name “PEPSET Part M”, Hodogaya Ash Land Co., Ltd.] and a curing catalyst [trade name “PEPSET Part K”, manufactured by Hodogaya Ashland Co., Ltd.].
結果を表２に示すが、ガス欠陥の評価は、◎がガス欠陥が見られない、○がガス欠陥が１〜４箇所ある、×がガス欠陥が５箇所以上あることを意味する。 The results are shown in Table 2. In the evaluation of gas defects, ◎ means that no gas defects are observed, ○ means that there are 1 to 4 gas defects, and × means that there are 5 or more gas defects.
表２中、ウレタンバインダー添加量は、鋳物砂１００重量部に対する量である。 In Table 2, the amount of urethane binder added is an amount based on 100 parts by weight of foundry sand.
また、実施例２と比較例１で得られた鋳物砂を用いて作製した鋳型の表面と、該鋳型を用いて作製した鋳物の表面の平滑性を、表面粗さ測定器（小坂研究所製、サーフコーダＳＥ-３０Ｈ）により表面粗さ〔中心線平均粗さ：Ｒａ（μｍ）〕として測定した。Ｒａが小さい程、表面平滑性に優れる。結果を下記表３に示す。表３に示されるように、実施例２の鋳物砂を用いた場合、比較例１の鋳物砂を用いた場合と比べ、表面平滑性に優れた鋳型が得られ、それを用いて作製した鋳物の表面も平滑性に優れることが分かる。 Further, the surface roughness measuring instrument (manufactured by Kosaka Laboratory) was used to determine the smoothness of the surface of the mold produced using the foundry sand obtained in Example 2 and Comparative Example 1 and the surface of the casting produced using the mold. , Surface roughness [centerline average roughness: Ra (μm)] using a surf coder SE-30H). The smaller the Ra, the better the surface smoothness. The results are shown in Table 3 below. As shown in Table 3, when the foundry sand of Example 2 was used, a mold having excellent surface smoothness was obtained as compared with the case of using the foundry sand of Comparative Example 1, and a casting produced using the same. It can be seen that the surface of is also excellent in smoothness.
＜実施例５〜９及び比較例４〜５＞
表１の鋳物砂を用いて、下記の方法により可使時間の評価を行った。結果を表４に示す。
＜可使時間の評価＞
表１の鋳物砂を１００重量部、ポリオール化合物の有機溶剤溶液〔商品名「ISOCURE パートＩ」、保土谷アシュランド（株）製〕を0.8重量部、及びポリイソシアネート化合物の有機溶剤溶液〔商品名「ISOCURE パートII」、保土谷アシュランド（株）製〕を0.8重量部、20℃にてミキサーにて混合して鋳型用混練砂を調製した。混練直後及び、混練２時間後（ポリカップに大気開放にて保存）に、それぞれ厚さ22ｍｍ×幅22ｍｍ×長さ180ｍｍの型に充填し、トリエチルアミンを砂に対して0.14重量％注入、気化させ、３０秒間通気し硬化させ、抜型した。抜型10分後に、曲げ強さ（抗折強度）を、GF抗折力試験機（支点間距離150mm）にて測定した。なお、強度低下率（％）は、〔（混練２時間後の抗折強度）／（混練直後の抗折強度）〕×１００で求めた。
<Examples 5-9 and Comparative Examples 4-5>
Using the casting sand of Table 1, the pot life was evaluated by the following method. The results are shown in Table 4.
<Evaluation of pot life>
100 parts by weight of the foundry sand in Table 1, 0.8 parts by weight of an organic solvent solution of a polyol compound [trade name “ISOCURE Part I”, manufactured by Hodogaya Ashland Co., Ltd.], and an organic solvent solution of a polyisocyanate compound [trade name “ISOCURE Part II” manufactured by Hodogaya Ashland Co., Ltd.] was mixed with 0.8 parts by weight of a mixer at 20 ° C. to prepare kneaded sand for casting. Immediately after kneading and after 2 hours of kneading (stored in a polycup in the open atmosphere), each was filled into a mold of 22 mm thickness x 22 mm width x 180 mm length, 0.14 wt% of triethylamine was injected into the sand and vaporized, It was cured by aeration for 30 seconds and then removed from the mold. Ten minutes after punching, the bending strength (bending strength) was measured with a GF bending strength tester (distance between fulcrums 150 mm). The strength reduction rate (%) was determined by [(Folding strength after 2 hours of kneading) / (Folding strength immediately after kneading)] × 100.
＜実施例１０及び比較例６〜７＞
表１の鋳物砂を用いて、下記の方法により自硬性鋳型法における鋳型強度の評価を行った。結果を表５に示す。
＜自硬性鋳型強度の評価＞
表１の鋳物砂（一部）を１００重量部、ポリオール化合物の有機溶剤溶液「パラセット パートR」、〔神戸理化（株）製〕を0.6重量部、及びポリイソシアネート化合物の有機溶剤溶液〔商品名「パラセット パートM」、神戸理化（株）製〕を0.6重量部、硬化触媒「パラセット パートK」神戸理化（株）製を0.03重量部、25℃にてミキサーにて混合して鋳型用混練砂を調製し、自硬性鋳型造型法に従ってφ50mm×50mm鋳型を作成し、混練終了後30分及び1日後（２４時間後）の圧縮強度試験機を用いて圧縮強度を測定した。
<Example 10 and Comparative Examples 6-7>
Using the casting sand of Table 1, the mold strength in the self-hardening mold method was evaluated by the following method. The results are shown in Table 5.
<Evaluation of self-hardening mold strength>
100 parts by weight of foundry sand (part) in Table 1, 0.6 parts by weight of an organic solvent solution “Paraset Part R” of a polyol compound [manufactured by Kobe Rika Co., Ltd.], and an organic solvent solution of a polyisocyanate compound [product] Name "Paraset Part M", manufactured by Kobe Rika Co., Ltd.] 0.6 parts by weight, curing catalyst "Paraset Part K" manufactured by Kobe Rika Co., Ltd. 0.03 parts by weight, mixed with a mixer at 25 ° C to mold A kneaded sand was prepared, a φ50 mm × 50 mm mold was prepared according to a self-hardening mold making method, and the compressive strength was measured using a compressive strength tester 30 minutes and 1 day after the kneading (24 hours later).
Claims (13)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2006020568A JP4877923B2 (en) | 2005-02-02 | 2006-01-30 | Spherical casting sand |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2005025872 | 2005-02-02 | ||
| JP2005025872 | 2005-02-02 | ||
| JP2006020568A JP4877923B2 (en) | 2005-02-02 | 2006-01-30 | Spherical casting sand |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2006239774A JP2006239774A (en) | 2006-09-14 |
| JP4877923B2 true JP4877923B2 (en) | 2012-02-15 |
Family
ID=37046676
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2006020568A Active JP4877923B2 (en) | 2005-02-02 | 2006-01-30 | Spherical casting sand |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP4877923B2 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP6367451B1 (en) * | 2017-11-10 | 2018-08-01 | 株式会社ツチヨシ産業 | Sintered artificial sand |
| CN112775391A (en) * | 2020-12-24 | 2021-05-11 | 天津宁康科技有限公司 | Low-gas-evolution high-strength quick-drying type repairing paste for furan resin sand and preparation method thereof |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2001205386A (en) * | 2000-01-28 | 2001-07-31 | Hodogaya Ashland Kk | Binder composition for casting of casting mold, composition for casting of casting mold and method for manufacturing casting mold for casting |
| JP3794944B2 (en) * | 2000-07-31 | 2006-07-12 | 保土谷アシュランド株式会社 | Manufacturing method of casting mold |
| JP4326916B2 (en) * | 2002-12-09 | 2009-09-09 | 花王株式会社 | Spherical casting sand |
-
2006
- 2006-01-30 JP JP2006020568A patent/JP4877923B2/en active Active
Also Published As
| Publication number | Publication date |
|---|---|
| JP2006239774A (en) | 2006-09-14 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US7987892B2 (en) | Spherical casting sand | |
| EP2513005B1 (en) | Foundry mixes containing sulfate and/or nitrate salts and their uses | |
| JP5794921B2 (en) | Casting sand mold and / or core manufacturing method and binder composition | |
| US10919085B2 (en) | Mold material mixture containing additives for reducing casting defects | |
| JP4877923B2 (en) | Spherical casting sand | |
| JP2011510819A (en) | Composition containing specific metallocene and use thereof | |
| JP4323187B2 (en) | Organic binder for mold, foundry sand composition obtained using the same, and mold | |
| WO2000005010A1 (en) | Coating compositions | |
| JP4421484B2 (en) | Organic binder for mold, foundry sand composition obtained using the same, and mold | |
| JPH08215788A (en) | Binder composition for casting mold, casting mold composition and production of casting mold | |
| WO2024079946A1 (en) | Cast shaping method and cast material | |
| JPH0669597B2 (en) | Low expansion mold material | |
| JP2001286977A (en) | Mold and method for manufacturing mold | |
| JPH02299741A (en) | Improvement of fluidity of resin-coated sand | |
| JP2004105982A (en) | Binder composition for amine gas hardening type mold, molding sand composition obtained from this binder and sand core for casting light alloy | |
| JPH10146647A (en) | Treatment of molding sand and manufacture of mold | |
| CN116586555A (en) | Application of environment-friendly clay green sand additive in cast iron | |
| CN112703070A (en) | Method for producing metal castings or hardened molded parts using aliphatic binder systems | |
| JPH0550175A (en) | Manufacture of casting sand mold | |
| JP2006187797A (en) | Coating agent composition for mold and mold coated thereof | |
| JP2000063624A (en) | Binding agent composition and preparation of molding using same |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| A621 | Written request for application examination |
Free format text: JAPANESE INTERMEDIATE CODE: A621 Effective date: 20081225 |
|
| A131 | Notification of reasons for refusal |
Free format text: JAPANESE INTERMEDIATE CODE: A131 Effective date: 20110614 |
|
| A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A523 Effective date: 20110811 |
|
| A131 | Notification of reasons for refusal |
Free format text: JAPANESE INTERMEDIATE CODE: A131 Effective date: 20110830 |
|
| A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A523 Effective date: 20111031 |
|
| TRDD | Decision of grant or rejection written | ||
| A01 | Written decision to grant a patent or to grant a registration (utility model) |
Free format text: JAPANESE INTERMEDIATE CODE: A01 Effective date: 20111122 |
|
| A01 | Written decision to grant a patent or to grant a registration (utility model) |
Free format text: JAPANESE INTERMEDIATE CODE: A01 |
|
| A61 | First payment of annual fees (during grant procedure) |
Free format text: JAPANESE INTERMEDIATE CODE: A61 Effective date: 20111124 |
|
| R151 | Written notification of patent or utility model registration |
Ref document number: 4877923 Country of ref document: JP Free format text: JAPANESE INTERMEDIATE CODE: R151 |
|
| FPAY | Renewal fee payment (event date is renewal date of database) |
Free format text: PAYMENT UNTIL: 20141209 Year of fee payment: 3 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
|
| R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |