CN103341621A - Subsurface-flow casting method - Google Patents
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- CN103341621A CN103341621A CN201310278329XA CN201310278329A CN103341621A CN 103341621 A CN103341621 A CN 103341621A CN 201310278329X A CN201310278329X A CN 201310278329XA CN 201310278329 A CN201310278329 A CN 201310278329A CN 103341621 A CN103341621 A CN 103341621A
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Abstract
The invention provides a subsurface-flow casting method and belongs to the technical field of casting. The subsurface-flow casting method comprises a first step of conducting layered slicing on a 3D model of a mould cavity of a casting mould, obtaining the layer thickness, the cross section area of the upper surface, and the size of each slice, setting parameters including the length of a pouring tube, the inner diameter of an opening of the pouring tube, the height from the opening of the pouring tube to the bottom of the mould cavity when mould filling begins, the distance between the opening of the pouring tube which is submerged in liquid and the liquid surface in the process of mould filling and the like, and working out the displacement-time relation of the liquid surface of the casting mould on the basis; a second step of lifting the pouring tube or lowering the casting mould according to the calculated displacement-time relation, wherein the opening of the pouring tube is submerged in the liquid and keeps a certain distance from the liquid surface all the time in the casting mould filling process. The subsurface-flow casting method has the advantages that the structure of a pouring system is simple, the material selection range of casting materials is wide, the size of a cast piece is not limited, and the liquid surface is stable in the process of mould filling. The subsurface-flow casting method further has the advantages that the upper portion of a temperature field is hot and the lower portion of the temperature filed is cold in the process of solidification, so that feeding is facilitated and the quality of the cast piece is good.
Description
Technical field
The invention belongs to casting technology field, relate to a kind of undercurrent casting method.
Background technology
Casting is Metal Melting to be smelt meet necessarily required liquid and water in casting mold, obtains the technical process of the foundry goods of reservation shape, size and performance through cooled and solidified, after leveling processing.
Casting is divided into sand casting and Special Processes of Metal Castings two big classes.Sand casting is to be the casting technique that main Modeling Material prepares casting mold with molding sand, Special Processes of Metal Castings are general names of other casting method except sand casting, and Special Processes of Metal Castings method commonly used has compression casting, model casting, centrifugal casting, lost foam casting etc.
(1) sand casting: be that Modeling Material is made casting mold with molding sand and core sand, liquid metal enters the casting method that casting mold is produced foundry goods by running gate system under gravity.Because the used Modeling Material of sand casting is cheap and easy to get, casting mold is made easy, to the single-piece production of foundry goods, produce by batch and produce in a large number and all can adapt to, for a long time, is the basic technology in the Foundry Production always.Steel, iron and most of non-ferrous alloy casting all available sand casting method obtain.
(2) compression casting: under the high pressure effect, with the die cavity of liquid state or the quick filling gold genotype of semi liquid state metal, and under pressure, be frozen into the casting method of foundry goods.Compression casting productivity ratio height is convenient to realize automation; The precision height of foundry goods, dimensionally stable, surface quality are good; That foundry goods is organized is fine and closely woven, mechanical property good; Can cast out complex-shaped thin-section casting.At present, compression casting is mainly used in producing in enormous quantities nonferrous metal and alloy components such as aluminium, zinc, copper, magnesium.
(3) model casting: making apperance with fusible material, be coated with in apperance and hang some layers of fireproof coating, melt the shell that apperance forms no die joint after waiting to harden, is the casting method of pourable acquisition foundry goods after high-temperature roasting.Model casting is a kind of precision casting process, and dimensional accuracy height, the surface quality of foundry goods are good; Adaptability is strong, can produce the complicated especially foundry goods of shape, is suitable for high-melting-point and difficult cutting alloy, and production lot is unrestricted.
(4) centrifugal casting: liquid metal is poured in the casting mold of rotation, at the centrifugal action lower charging type and be frozen into the casting method of foundry goods.The characteristics of centrifugal casting are molten metals at the centrifugal action lower charging type and solidify that the metal feeding is effective, the densification of foundry goods outer tissue, and non-metallic inclusion is few, good mechanical property; Without moulding, coremaking, saved associated materials and equipment and dropped into.Centrifugal casting is widely used in the production of large-diameter cast iron pipe, cylinder sleeve, bimetallic bearing, piston ring, special steel seamless tube blank etc.
(5) lost foam casting: adopt the foamed material apperance to replace the moulding of common apperance consolidation, do not take out apperance after having made type, direct casting of molten metal, under the effect of high-temperature liquid metal, apperance be heated gasification, the burning and disappear, molten metal replaces the position that original Foam Pattern occupies, and namely obtains required foundry goods after the cooled and solidified.Lost foam casting has simplified formative technology greatly, and has reduced casting flaw and the quantity scrapped that is caused by coremaking, delivery, mould assembly without molding, without core, mould assembly not.Be applicable to all kinds of alloys (steel, iron, copper, aluminum), be suitable for complex structure, be difficult to molding or loose piece and the more foundry goods of outer core.
More than various casting methods characteristics and advantage are respectively arranged, still, also all exist some shortcomings.For sand casting, running gate system constitutes complicated, comprise cup, cross gate, sprue, ingate, rising head, exhaust duct etc., each part is obvious to the influence of liquid metal filling and process of setting, but design difficulty is bigger, simultaneously, because the influence of factor such as casting process complexity and sand bond be lower is easy to generate defectives such as sand holes, cold shut, pore, shrinkage porosite.
For compression casting, can not be used for the production of high-melting-point cast iron and steel-casting at present; Because poring rate is big, often has pore to residue in the foundry goods, so the unsuitable heat treatment of foundry goods, in case when gases are heated, they expand, cause casting deformation to break.In addition, the compression casting equipment investment is big, and the die-casting die manufacturing cycle is long, cost is high.
For model casting, complex process, production cycle length, raw and auxiliary material expense are than sand casting height, and production cost is higher, is not suitable for the very big foundry goods of production overall size.
For centrifugal casting, the cylindrical part endoporus Free Surface that casts out is coarse, scale error is big, of poor quality, and increased number of stomata, slag inclusion are arranged, and therefore needing increases allowance, and is not suitable for pouring into a mould alloys such as the alloy that is easy to generate gravity segregation and magnalium.
For lost foam casting, gasified pattern causes air pollution; The foamed plastics mould design production cycle is long, the cost height; When producing large-sized foundry goods, apperance is yielding.
Summary of the invention
The invention provides a kind of method of making foundry goods based on the undercurrent foundry engieering.
Technical scheme of the present invention may further comprise the steps:
Step 1: draw the three-dimensional CAD model of casting mold, along perpendicular to gravity direction the casting mold die cavity being carried out hierarchy slicing, calculate and store bed thickness, upper surface sectional area, the volume of every layer of section; Draw the three-dimensional CAD model of casting ladle, along perpendicular to gravity direction the casting ladle inner chamber being carried out hierarchy slicing, calculate and store bed thickness, upper surface sectional area, the volume of every layer of section.The section of layering is more thin, the number of plies is more many, and then the subsequent calculations precision is more high, but separation time increases.
Step 2: set the cast parameter, comprise molten metal weight W to be poured in the casting ladle
0Reach density p, gate spool length L
Pipe, cast mouth of pipe inner diameter D
Pipe, when filling type and beginning the cast mouth of pipe apart from the height H of cavity bottom
0, the cavity filling process cast mouth of pipe slips into level H
Dive, monitoring period T
Prison, weight error permissible value α etc.
Step 3: the cast parameter of setting according to step 2, the cavity filling process of casting mold in the step 1 is calculated, obtain following result: from beginning to fill type arrives the cast mouth of pipe to liquid level time T
H0, arriving the cast mouth of pipe from liquid level, to flood the mouth of pipe degree of depth to liquid level be H
DiveTime T
H dives, for guaranteeing that the cast mouth of pipe slips into level and is stabilized in H
DiveDisplacement-the time relationship of gate spool or casting mold.
Step 4: the three-dimensional CAD model according to casting mold in the step 1 is made casting mold; According to step 2 relevant parameter, the original state of system is set.
Step 5: will water to wrap for the stopper rod of regulating flow and open, gate spool begins liquid level rising in cast, the casting mold.Calculate the gained result according to step 3, the displacement of regulation and control gate spool or casting mold is so that the cast mouth of pipe slips into level and is stabilized in H in the cavity filling process
Dive
When casting mold fills type, every time T
Prison, with the measured value W of casting mold inner metal liquid weight
SurveyWith calculated value W
MeterCompare, if │ W
Survey-W
Meter│
Scaleα, be moved to │ W by what regulate flow, adjust the gate spool displacement or adjust casting mold
Survey-W
Meter│＜α.
Step 6: after filling type and finishing, take out gate spool.After treating that foundry goods solidifies cooling fully, casting mold opened foundry goods is taken out.
Effect of the present invention and benefit are:
(1) undercurrent casting is a kind of new casting method, and the cavity filling process liquid level is steady, flow velocity is controlled, can effectively reduce owing to filling casting flaws such as sand holes that type produces out of order, pore, slag inclusion; Foundry goods can form the temperature field of upper heat and lower cold when solidifying, be conducive to the feeding of foundry goods, improves casting quality.
(2) running gate system is simple in structure, does not need to design complicated running channel, only needs one " gate spool " can realize that molten metal steadily charges into casting mold.
(3) castings material and size restrictions are little, are widely used in the ferrous and nonferrous metals, and the foundry goods shape can be very complicated.
(4) the mold material selection is extensive, molding sand, core sand, metal, pottery etc. all can, mould dimension is unrestricted, applicability is good, practical.
Description of drawings
Fig. 1 is system schematic of the present invention.
Fig. 2 a, Fig. 2 b, Fig. 2 c and Fig. 2 d are cavity filling process schematic diagram of the present invention.
Fig. 3 is the embodiment of the invention 1 target formed body " tire tread block " three-dimensional CAD figure.
Fig. 4 is the displacement-time graph that the gate spool of the embodiment of the invention 1 promotes.
Fig. 5 is the embodiment of the invention 2 target formed bodys " 7 vane propeller " three-dimensional CAD figure.
Fig. 6 is the displacement-time graph that the gate spool of the embodiment of the invention 2 promotes.
Among the figure: 1 molten metal to be poured; 2 stopper rods; 3 casting ladles; 4 lifters; 5 casting molds; 6 casting mold die cavities; 7 casting mold die cavity inner metal liquids; 8 electronic scales.
The specific embodiment:
Below in conjunction with technical scheme and accompanying drawing, be described in detail most preferred embodiment of the present invention.
Embodiment 1: undercurrent casting " tire tread block " foundry goods, aluminium alloy
Adopt the 3D model of Solidworks drafting " tire tread block " casting mold, as shown in Figure 3.Along perpendicular to gravity direction the casting mold die cavity being carried out hierarchy slicing, lift height 1mm, 337 layers altogether, information such as the bed thickness of calculating and every layer of section of storage casting mold die cavity, upper surface sectional area, volume.The casting ladle inner chamber is cuboid in this example, perpendicular to gravity direction sectional area A (i)=0.021m
2
Set the cast parameter:
Aluminum alloy melt gross weight W to be poured in the casting ladle
0=10.80kg, density p=2400kg/m
3
The gate spool length L
Pipe=0.35m, cast mouth of pipe inner diameter D
Pipe=0.014m;
The cast mouth of pipe is apart from the height H of cavity bottom when initial
0=0.020m;
The cavity filling process mouth of pipe slips into level H
Dive=0.025m;
According to the cast parameter of setting, " tire tread block " casting mold cavity filling process is calculated, mainly comprise three phases:
Stage one: arrive the cast mouth of pipe to liquid level from beginning to fill type.
Following equations simultaneousness is got up to carry out iterative computation:
H=H
1 
Q=v Δ tA
PipeH
1=H
1-q/A (i); H
2=H
2+ q/A (j)
In the formula: H, cast mouth of pipe pressure head, m; H
1, liquid level in the casting ladle, m; V, cast mouth of pipe flow stream velocity m/s; G, acceleration of gravity, 9.80m/s
2μ, discharge coefficient, this routine value is 0.50; Q, unit step-length time mouth of pipe flow, m
3Δ t, the unit step-length time, this routine value is 0.05s; A
PipeGate spool internal diameter sectional area, m
2A (i), casting ladle inner chamber i layer upper surface sectional area, m
2H
2, liquid level in the casting mold, m; A (j), casting mold die cavity j layer upper surface sectional area, m
2
Through iterative computation, obtain from beginning to fill type arrives the cast mouth of pipe to liquid level time T
H0
Stage two: flooding the mouth of pipe degree of depth from the liquid level arrival cast mouth of pipe to liquid level is H
Dive
Following equations simultaneousness is got up to carry out iterative computation:
H=H
1+ L
Pipe+ H
0-H
2 
Q=v Δ tA
PipeH
1=H
1-q/A (i); H
2=H
2+ q/A (j)
In the formula: L
Pipe, gate spool length, m; H
0, the cast mouth of pipe is apart from the height of cavity bottom, m when initial.
Through iterative computation, obtaining flooding the mouth of pipe degree of depth from the liquid level arrival cast mouth of pipe to liquid level is H
DiveRequired time T
H dives
Stage three: for guaranteeing that the cast mouth of pipe slips into level and is stabilized in H
DiveGate spool is promoted.
Following equations simultaneousness is got up to carry out iterative computation:
H
r=H
r+ H
R1H=H
1+ L
Pipe+ H
0-H
2+ H
r 
Q=v Δ tA
PipeH
1=H
1-q/A (i); H
2=H
2+ q/A (j)
In the formula: H
r, gate spool hoisting depth, m; H
R1, gate spool promotes unit step-length displacement, this routine value 0.002m.
Through iterative computation, obtain gate spool and promote displacement-time relationship.
After calculating is finished, stage one, stage two, stages three result of calculation are merged, obtain gate spool lifting displacement-time relationship that casting mold fills the type overall process, as shown in Figure 4.
According to the three-dimensional CAD model of casting mold, adopt precoated sand to make casting mold.According to setting the cast parameter, the original state of system is set.
Stopper rod is opened, gate spool begins cast, and liquid level begins to rise in the casting mold, slips into after level is 0.025m at the cast mouth of pipe, gate spool is promoted by calculating gained displacement-time relationship, make that the cast mouth of pipe slips into the degree of depth in the cavity filling process to be stabilized in about 0.025m.
After filling type and finishing, gate spool is taken out.Treat that the foundry goods cooled and solidified after room temperature, opens casting mold, obtain " tire tread block " aluminium alloy castings.
Embodiment 2: undercurrent casting " 7 vane propeller " foundry goods, copper alloy
Adopt the 3D model of Solidworks drafting " 7 vane propeller " casting mold, as shown in Figure 5.Along perpendicular to gravity direction the casting mold die cavity being carried out hierarchy slicing, the thickness 0.5mm of layering, 560 layers altogether, information such as the bed thickness of calculating and every layer of section of storage casting mold die cavity, upper surface sectional area, volume; The casting ladle inner chamber is cuboid in this example, perpendicular to gravity direction sectional area A (i)=0.021m
2
Set the cast parameter:
Copper alloy liquid gross weight W to be poured in the casting ladle
0=45.75kg, density p=7800kg/m
3
The gate spool length L
Pipe=0.35m, cast mouth of pipe inner diameter D
Pipe=0.014m;
The cast mouth of pipe is apart from the height H of cavity bottom when initial
0=0.020m;
The cavity filling process mouth of pipe slips into level H
Dive=0.025m;
According to the cast parameter of setting, " 7 vane propeller " casting mold cavity filling process is calculated, mainly comprise three phases:
Stage one: arrive the cast mouth of pipe to liquid level from beginning to fill type.
Following equations simultaneousness is got up to carry out iterative computation:
H=H
1 
Q=v Δ tA
PipeH
1=H
1-q/A (i); H
2=H
2+ q/A (j)
In the formula: H, cast mouth of pipe pressure head, m; H
1, liquid level in the casting ladle, m; V, cast mouth of pipe flow stream velocity m/s; G, acceleration of gravity, 9.80m/s
2μ, discharge coefficient, this routine value is 0.50; Q, unit step-length time mouth of pipe flow, m
3Δ t, the unit step-length time, this routine value is 0.05s; A
PipeGate spool internal diameter sectional area, m
2A (i), casting ladle inner chamber i layer upper surface sectional area, m
2H
2, liquid level in the casting mold, m; A (j), casting mold die cavity j layer upper surface sectional area, m
2
Through iterative computation, obtain from beginning to fill type arrives the cast mouth of pipe to liquid level time T
H0
Stage two: flooding the mouth of pipe degree of depth from the liquid level arrival cast mouth of pipe to liquid level is H
Dive
Following equations simultaneousness is got up to carry out iterative computation:
H=H
1+ L
Pipe+ H
0-H
2 
Q=v Δ tA
PipeH
1=H
1-q/A (i); H
2=H
2+ q/A (j)
In the formula: L
Pipe, gate spool length, m; H
0, the cast mouth of pipe is apart from the height of cavity bottom, m when initial.
Through iterative computation, obtaining flooding the mouth of pipe degree of depth from the liquid level arrival cast mouth of pipe to liquid level is H
DiveRequired time T
H dives
Stage three: for guaranteeing that the cast mouth of pipe slips into level and is stabilized in H
DiveGate spool is promoted.
Following equations simultaneousness is got up to carry out iterative computation:
H
r=H
r+ H
R1H=H
1+ L
Pipe+ H
0-H
2+ H
r Q=v Δ tA
PipeH
1=H
1-q/A (i); H
2=H
2+ q/A (j)
In the formula: H
r, gate spool hoisting depth, m; H
R1, gate spool promotes unit step-length displacement, this routine value 0.002m.
Through iterative computation, obtain gate spool and promote displacement-time relationship.
After calculating is finished, stage one, stage two, stages three result of calculation are merged, obtain gate spool lifting displacement-time relationship that casting mold fills the type overall process, as shown in Figure 6.
According to the three-dimensional CAD model of casting mold, adopt precoated sand to make casting mold.According to setting the cast parameter, the original state of system is set.
Stopper rod is opened, gate spool begins cast, and liquid level begins to rise in the casting mold, slips into after level is 0.025m at the cast mouth of pipe, gate spool is promoted by calculating gained displacement-time relationship, make that the cast mouth of pipe slips into the degree of depth in the cavity filling process to be stabilized in about 0.025m.
After filling type and finishing, gate spool is taken out.Treat that the foundry goods cooled and solidified after room temperature, opens casting mold, obtain " 7 vane propeller " copper-alloy casting.
Claims (2)
1. undercurrent casting method, its characterization step is as follows:
Step 1: draw the three-dimensional CAD model of casting mold, along perpendicular to gravity direction the casting mold die cavity being carried out hierarchy slicing, calculate and store bed thickness, upper surface sectional area, the volume of every layer of section; Draw the three-dimensional CAD model of casting ladle, along perpendicular to gravity direction the casting ladle inner chamber being carried out hierarchy slicing, calculate and store bed thickness, upper surface sectional area, the volume of every layer of section; The section of layering is more thin, the number of plies is more many, and then the subsequent calculations precision is more high, but separation time increases;
Step 2: set the cast parameter, comprise molten metal weight W to be poured in the casting ladle
0Reach density p, gate spool length L
Pipe, cast mouth of pipe inner diameter D
Pipe, when filling type and beginning the cast mouth of pipe apart from the height H of cavity bottom
0, the cavity filling process cast mouth of pipe slips into level H
Dive, monitoring period T
Prison, weight error permissible value α;
Step 3: the cast parameter of setting according to step 2, the cavity filling process of casting mold in the step 1 is calculated, obtain following result:
From beginning to fill type arrives the cast mouth of pipe to liquid level time T
H0
Flooding the mouth of pipe degree of depth from the liquid level arrival cast mouth of pipe to liquid level is H
DiveTime T
H dives
For guaranteeing that the cast mouth of pipe slips into level and is stabilized in H
DiveDisplacement-the time relationship of gate spool or casting mold;
Step 4: the three-dimensional CAD model according to casting mold in the step 1 is made casting mold and step 2 relevant parameter, and the original state of system is set;
Step 5: will water to wrap for the stopper rod of regulating flow and open, gate spool begins liquid level rising in cast, the casting mold; Calculate the gained result according to step 3, the displacement of regulation and control gate spool or casting mold is so that the cast mouth of pipe slips into level and is stabilized in H in the cavity filling process
Dive
Step 6: after filling type and finishing, take out gate spool.After treating that foundry goods solidifies cooling fully, casting mold opened foundry goods is taken out.
2. a kind of undercurrent casting method according to claim 1 is characterized in that:
When casting mold fills type, every time T
Prison, with the measured value W of casting mold inner metal liquid weight
SurveyWith calculated value W
MeterCompare, if │ W
Survey-W
Meter│
Scaleα, be moved to │ W by what regulate flow, adjust the gate spool displacement or adjust casting mold
Survey-W
Meter│＜α.
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|---|---|---|---|
| CN201310278329.XA CN103341621B (en) | 2013-07-03 | 2013-07-03 | Subsurface-flow casting method |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201310278329.XA CN103341621B (en) | 2013-07-03 | 2013-07-03 | Subsurface-flow casting method |
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| Publication Number | Publication Date |
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| CN103341621A true CN103341621A (en) | 2013-10-09 |
| CN103341621B CN103341621B (en) | 2015-04-08 |
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| CN106493312A (en) * | 2016-12-07 | 2017-03-15 | 丹东华强有色金属加工有限公司 | One Albatra metal floating apparatus for pouring and method |
| CN106493313A (en) * | 2016-12-07 | 2017-03-15 | 丹东华强有色金属加工有限公司 | One Albatra metal floating pouring procedure |
| CN108421969A (en) * | 2018-05-28 | 2018-08-21 | 广西南丹南方金属有限公司 | A kind of automatic casting system |
| CN109434022A (en) * | 2019-01-05 | 2019-03-08 | 施小建 | Cast displacement type running gate system |
| CN114669719A (en) * | 2022-03-16 | 2022-06-28 | 河南科技大学 | Sand casting device for hot-working process database |
| CN115647343A (en) * | 2022-10-13 | 2023-01-31 | 哈尔滨理工大学 | Liquid metal mold filling capacity evaluation method and test device |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106493312A (en) * | 2016-12-07 | 2017-03-15 | 丹东华强有色金属加工有限公司 | One Albatra metal floating apparatus for pouring and method |
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| CN109434022A (en) * | 2019-01-05 | 2019-03-08 | 施小建 | Cast displacement type running gate system |
| CN109434022B (en) * | 2019-01-05 | 2024-05-31 | 施小建 | Casting deflection type pouring system |
| CN114669719A (en) * | 2022-03-16 | 2022-06-28 | 河南科技大学 | Sand casting device for hot-working process database |
| CN114669719B (en) * | 2022-03-16 | 2024-06-04 | 河南科技大学 | Sand casting device for hot processing technology database |
| CN115647343A (en) * | 2022-10-13 | 2023-01-31 | 哈尔滨理工大学 | Liquid metal mold filling capacity evaluation method and test device |
Also Published As
| Publication number | Publication date |
|---|---|
| CN103341621B (en) | 2015-04-08 |
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