JPS61188368A - Method of manufacturing traverse drum - Google Patents

Abstract

PURPOSE:To make it possible to provide a thin wall drum made of iron group materials, by charging a particulate or powder material which is hardenable or fluidizingable, in the inside space of a film which defines a predetermined shape of a molding core so that pattern models between shell layers formed on the inner and outer surfaces of the film is vanished by melting. CONSTITUTION:A cylindrical chamber 7 is formed having a space 6 defined around a core mould die 4 composed of splitted die pieces 4a-4n. At first a stretchable film 5 softened by heating is inserted into the cylindrical chamber 7 along the inner wall 2 of the mould die 4. Then, the film 5 is sucked closely onto the inner wall 2 through suction holes 8. A powder or paticulate material 10 such as, for example, sand, metallic fine particles, piece balls, etc. is charged into the inside space of the film 5 defining a drum-like space to form a film skin layer on the outer peripheral surface of the material 10, and air withing the material 10 is sucked to reduce the pressure thereof in order to bind and harden the material 10. Further, a mould core 12 is set in the mould die, and a molten material is filled in the thus formed cavity 14. After removal of a mould die 13 and a cap 15 and stopping of suction, a pattern model 19 may be obtained.

Description

[Detailed description of the invention] [Industrial application field] The present invention relates to a method for manufacturing a traverse drum.

[Conventional technology]

There are various types of grooved traverse drums used in automatic winders for winding yarn, but the above-mentioned traverse drum rotates the winding package at high speed through surface contact and traverses the yarn pulled out from the yarn supply at high speed. Various conditions are required for the vibrating drum, and in terms of functionality, they are: 1) It must be a conductor to dissipate the static electricity generated during winding and prevent static electricity; 2) The part that comes in contact with the thread must be wear-resistant; 3) The drum must be resistant to wear. It also prevents the ribbon winding that occurs when the diameter of the package and package are at a certain ratio, 2) It is lightweight to stop the drum when the thread breaks, and 2) The friction coefficient of the drum surface is low. (e) It must be easy to process, including complex groove machining; and) It must have stable accuracy and be low in cost.

Various types of drums are produced from this point of view. Regarding (a), for example, there are drums in which a coating of an antistatic agent or an antistatic agent is coated on the surface of the drum, but there are problems with abrasion of the coating and abrasion of the base body. Regarding thread openings, hard metal or ceramic pins are embedded in the thread guide to prevent wear, but machining is troublesome and there are problems in terms of quality and cost.

Furthermore, regarding (2) and (e), we are currently planning to reduce the weight to 1.5 K9 to 2.0 K9 by using an aluminum alloy for the drum base as the easiest way to reduce the weight. Because it is made of aluminum, it has poor wear resistance, so the surface is hard alumite treated, but the hardness is only about 500 HV at most, and the alumite coating is non-conductive, so static electricity will not build up. There is a problem with doing so.

Therefore, in order to improve wear resistance, it is desirable to use iron-based alloy materials, but the specific gravity
．． It is 6 to 3.1 times. In addition, it has a high melting point and is expensive to manufacture (and is difficult to process as it is harder than aluminum, making it difficult to process), so drums made of iron-based materials are still rarely used regularly.

[Problem that the invention seeks to solve]

The present invention relates to a method for manufacturing an extremely thin-walled ferrous metal drum, and particularly an object of the present invention is to provide a method convenient for manufacturing a thin-walled drum by casting.

[Means to solve the problem]

In the step of forming a drum original product of a meltable material by pouring the meltable material into a limited space between a drum-shaped female mold and a core set in the mold, the core is In the step of filling the internal space of a film limited to a certain shape with particles or powder that can be hardened and fluidized, and further forming a refractory shell layer on the inner and outer surfaces of the original product. Subsequently, the process consists of melting and extinguishing the original product in the shell layer and pouring molten metal into the internal space of the shell layer.

[For production]

The above-mentioned core is made by filling a film-like film with a drum-shaped limited space with granules or powder, and then hardening the film by sucking and reducing the pressure in the film.
The original product can be molded by placing it in a female mold and pouring melting material into it. After being solidified into the original shape, the hardened particles within the coating are returned to the atmosphere, whereupon they are decomposed into the original particles and flow out as particles.

This granule can be used repeatedly to make cores.

〔Example〕

Embodiments of the present invention will be described below with reference to the drawings.

(Il Core making process Figures 2 to 5 show an example of the core making process. vinegar.

The apparatus and materials for making the core include a cylindrical female mold which is fixed in position on a movable table (1) and has a convex band (3) for traverse grooves formed on its inner wall (2). It consists of a mold (4), a film (5) inserted into the mold (4), granules or powder filled into the film, and a vacuum decompression or vacuum pump device (not shown).

The above-mentioned core mold (4) is designed so that the divided mold pieces (4a) to (4n) can be opened and closed radially as shown in Fig. 6, and Fig. 7 shows the divided mold pieces (4a) to (4n) in the open state. 4゜ Each of the mold pieces (4a) to (4n) has a space (6) closed on all four sides as shown in Fig. 2, and each space communicates with the gap between the closed mold pieces. A cylindrical chamber (7) is configured. Above chamber (7) and mold inner wall (2)
A suction hole (8) is bored at an appropriate position in between, and the chamber (7) has a communication hole (8) connected to a vacuum device (not shown).
9) are formed and connected by pipes.

To make a core using such a mold, first heat the stretchable film (5) to a slightly softened extent as shown in Figure 2, and then press the inner wall (2) of the mold (4).
Insert the film along the lines.

Then, the vacuum device is activated to create a negative pressure in the chamber (7), and a suction action is created between the inner wall: 2) and the film (5) through the suction hole (8), and the film (5) It is sucked and comes into close contact with the inner wall surface (2). At this time, it is convenient if the suction holes (8) are evenly distributed over the entire inner wall of the mold, so that the film can be brought into close contact with the entire film with substantially equal suction force.

Next, powder or granular materials such as sand, fine metal particles, or fine piece beads (
Pour the powder or granules (10) into the drum-shaped powder or granules (10), and place the same film (5) on top of the powder or granules (10) while applying a slight vibration.
) with a film layer formed around the outer periphery. In this state, the suction hole (11) formed in the table (1)
) and the air in the filler (10) is strongly sucked and depressurized through the fine pores formed in the film (5) on the lower surface, so that the powder or granules (10) inside becomes hard (hardened by bonding). .

While the suction action continues, the mold (4) is opened radially as shown in Figure 7, and the core (12
) is completed (Figure 5).

(II) Manufacturing process of meltable drum original product A splittable female mold (13) corresponding to the shape of the surface of the drum to be manufactured is opened as in the case of FIG. Core (1) made with +I)
2) is moved together with the table (1) and set in the mold, the mold is closed, and the mold is set in the state shown in FIG. That is, the outer surface of the core (12) on the table (1) and the mold (
4) between the inner surfaces of the thin-walled, limited drum-shaped space (1
4) is formed. A meltable material, such as a wax or urea resin melt that is easily melted by heating at 60 to 140° C., is injected into the space (14). In FIG. 8, (15) is the cap of the mold (14) in which pouring holes (16) (16) are formed. FIG. 10 is a partial perspective view of the mold (13) in a closed state, and when the divided mold pieces (13a) to (13n) are closed, a drum groove is formed on the inner surface (17). A continuous convex band (18) is formed.

Information on the above space (14) Wait until the injected molten liquid such as wax solidifies, remove the cap (15) and mold (13) in Figure 8, and continue to suck air from the core (12). When the suction is stopped, the powder or granules (10) filled inside the core flow out, and a film coating (19) is formed on the inner surface of the original product (19), as shown in Only 5) remains. Subsequently, the film (5) is completely removed, thereby completing a meltable drum prototype (19). The size of the original product (19) is larger than the final drum size by the amount of shrinkage.

Field Production process of shell for metal injection Melting drum original product obtained in step m (19)
and the male mold for metal injection cap (20) made of the same material as the original product are glued together and the surface of the resulting product is thoroughly cleaned with detergent etc., and the integrated product of the original product (19) and the cap (20) ( (Fig. 11) is poured into a specific liquid mixture, and a refractory material is attached to the surface of the integrated object.

The above-mentioned mixed liquid hole is a mixed liquid of zircon flour and ethyl silicate, for example, with a liquid temperature of 20-30°C and a concentration of 40-80°C.
% is appropriate. After dipping into the mixed solution, take out the integrated object (19) (2C1) from the mixed solution, sprinkle zircon sand on its surface and let it dry a little. After further drying, add another mixed solution fB), for example zircon sand. Dip into a mixed solution of sodium silicate, and sprinkle a refractory material such as chamotte sand on the surface to be taken out.

After further drying, a depping treatment and a refractory adhesion treatment are performed, such as dipping into another mixed liquid (C1, for example, a mixed liquid of mullite flour and ethyl silicate, and then sprinkling a refractory such as molochite on the surface). Repeat 5-10 times alternately until the thickness of the refractory (21) is 6-15
A shell layer (21) of approximately ff, that is, an appropriate thickness that does not interfere with the pouring process and the process of taking out the finished product, is formed.

As shown in Figure 11 (after drying the refractory shell layer (21) on the surface of the meltable prototype (19) for a certain period of time, the integrated product is heated under certain conditions to form a drum prototype ( 19) and the male cap mold (20) are melted.

Under a certain temperature condition, the drum original product (19) and the male cap mold (20) are melted to form a refractory shell mold (21) having a drum shape and a certain space. The mold is fired at high temperatures (900°C to 1100°C) to burn off impurities.

■ Non-oxidizing pouring process The material of the drum, in this example, a molten iron-based metal, is poured in a non-oxidizing state into the limited extremely thin space of the refractory mold manufactured in the above step (to). to quickly inject and manufacture drums.

FIG. 12 shows an example of a pouring device. That is, the mold (21) is fixedly installed on a fixed plate (24) in a processing chamber (23) covered with a cover (22). At the bottom of the plate (24) is a furnace (25) in which molten metal (25) is stored.
26) is the installation. Further, the plate (24) is provided with a stalk-shaped hole (27) for passage of the melt.

After setting in the above condition, the furnace (
Argon gas is pressurized into the space (29) of 26), and the hot water surface (30) is constantly kept in a non-oxidized state by the argon gas.
When gas pressure is applied to the surface of the hot water, the hot water is forced into a limited drum-like space in the mold (21) through a stalk-shaped pipe (27) that is not under pressure.

Since the drum-shaped thin space described above has grooves with a complicated shape, in the normal pouring method performed in the atmosphere, the molten metal undergoes an oxidation reaction with oxygen before being poured into every corner of the space. Although it is difficult to inject into the entire thin space, by injecting it in the above-mentioned non-oxidized state, the molten material can be quickly and quietly poured into the mold without causing any oxidation reaction in a clear stream without introducing impurities. It is injected into the entire space within (21).

In addition, in Fig. 12, the furnace (26) is in communication with the molten metal replenishment furnace (31, with lid G32).
can be opened to replenish the molten metal in the ladle (33). If a small amount of argon gas is also supplied from the pipe (35) into the space (34) of the replenishment furnace (31), the argon gas, which has a higher specific gravity than air (1,38), will always be in contact with the hot water surface (36). ,
The hot water surface (36) is maintained in a non-oxidized state.

In addition, (37) is an induction heating coil, (38) is an electric heater for keeping molten metal warm.

■ Post-processing and finishing process The metal drum removed from the refractory mold is heat-treated to eliminate casting stress, and the drum surface and grooves are processed to improve the roundness and balance of the drum. The surface is polished using a lapping machine or puff polishing to create a surface with a low coefficient of friction.

Additionally, surface treatment is applied to increase the hardness of the drum surface and grooves. For example, when ion nitriding, ion brating, etc. are applied, the hardness of the drum surface immediately after casting (200 to 400 HV) is 800 to 20.
A drum with a hardness of 0.00HV and excellent wear resistance is manufactured.

FIG. 1 schematically shows the above steps.

That is, the step of manufacturing the core (12) is the step of manufacturing the core (12).
Step (IF) of manufacturing a meltable original product (19) using 2).

A shell (21) made of refractory material using the above original product (19)
Step 2 of injecting the molten metal into the shell (21) under non-oxidizing conditions;
) and a step (2) of performing post-treatment including surface treatment. The finished drum product (41) obtained by such a manufacturing method satisfies all the conditions required as a traversing drum for an automatic wine gourd, as described above.

In each of the above steps, the materials, processing liquids, etc. used may be those that meet various conditions (various materials or combinations are possible).

In addition to iron-based metals, we also manufacture parts with relatively simple shapes or combinations of parts that do not have complicated grooves, such as traverse drums, as well as zinc alloys, aluminum alloys, magnesium alloys, copper alloys, etc. When manufacturing in this way, non-oxidizing injection or injection in the atmosphere is also possible.

Effects of the Invention As described above, according to the present invention, it is possible to manufacture a traversing drum made of iron-based metal that is extremely thin, lightweight, and has excellent conductivity and wear resistance. In particular, the granules or powder forming the core can be used repeatedly, and according to the present invention, the entire process can be automated, which is economical.

[Brief explanation of drawings]

Figure 1 is a schematic diagram showing the drum manufacturing process, Figures 2 to 5
The figures show the core making process. Figure 2 is the process of inserting the film, Figure 3 is the process of pouring the filler material into the film, Figure 4 is the process of hardening the filler material by vacuum, and Figure 5 is the process of making the core. 6 is a partially sectional front view showing the completed core, FIG. 6 is a plan view showing the divided mold for the core in a closed state, and FIG. 8 is a cross-sectional front view showing the molded state of the original drum product, FIG. 9 is a front view showing the completed state of the original product, and FIG. 10 is a portion showing the mold (13) in a closed state. Perspective view, 11th
The figure is a cross-sectional front view showing the manufacturing process of a refractory shell, and FIG. 12 is a schematic configuration diagram showing an example of an oxidation-free pouring apparatus for molten metal. (4) ... Film (10) ... Granules or powder (12) ... Core (13) ... Mold (14) ... Space (19) ... Original product ( 21) ... Shell layer (25), z. Molten metal Fig. 7

Claims (1)

[Claims] Drum-shaped products made of meltable material A female mold with a shape and a medium set inside the mold. Pouring meltable material into the limited space between the tubes In the step of forming the core, the core is A hard material is applied to the inner space of the film, which is limited to a certain shape. Filled with granules or powder that can be liquefied or fluidized. In addition to forming the above-mentioned original product, Process of forming a refractory shell layer on the outer surface Subsequently, melting the original part within the shell layer above melted metal into the internal space of the shell layer. and a step of pouring hot water. A method of manufacturing a traverse drum.