CN103468893B - Quenching unit and its application method for Complex Aluminum Alloy Casting with Thin Wall Thickness - Google Patents

Abstract

It is a set of for realizing the cooling of casting Quick uniform in Complex Aluminum Alloy Casting with Thin Wall Thickness quenching process, reducing casting deformation and improving the device of mechanical property present invention aims at providing.

Description

Quenching unit and its application method for Complex Aluminum Alloy Casting with Thin Wall Thickness

Technical field

The present invention relates to a set of dresses for realizing the cooling of Complex Aluminum Alloy Casting with Thin Wall Thickness quenching process Quick uniform It sets and its application method.

Background technology

In fields such as aerospace, weaponry, automobile, ships, large-scale complex thin-wall casting is especially large complicated thin Wall aluminum alloy cabin, the demand of box casting and application are just more and more extensive.

Subsequent heat treatment modification will be generally carried out after Complex Aluminum Alloy Casting with Thin Wall Thickness molding, it is therefore an objective to it is strong to improve it Degree, hardness, anti-fatigue performance etc..But due to complicated, thin-walled, large size, and during heat treatment because be related to heating, it is cold But, many factors comprehensive function such as stress, frequently results in that casting deformation is serious, even across the artificial orthopedic of multi-pass, casting Qualification rate is still relatively low, it is difficult to meet design requirement of the product to high-quality high-precision casting.Currently, domestic for large complicated The serious problem of thin-walled aluminium alloy castings heat-treatment distortion also expands correlative study, is concentrated mainly on preferred hardening media and quenches Distortion correction new process etc. after fiery mode reduces heavy castings distorsion during quenching, development is heat-treated, and achieve certain effect Fruit, but be heat-treated after deform or it is larger, dimension precision requirement cannot be met.Casting quench the type of cooling to cast properties and Dimensional accuracy is affected, the splash cooling system of reasonable design, helps to realize the Quick uniform cooling of casting thin and thick position, carries Reducing deformation while high mechanical castings.

Invention content：

It is a set of for realizing that casting is fast in Complex Aluminum Alloy Casting with Thin Wall Thickness quenching process present invention aims at providing It is fast uniformly cooling, it reduces casting deformation and improves the device of mechanical property.

It is another object of the present invention to provide a kind of above-mentioned apparatuses to quench for Complex Aluminum Alloy Casting with Thin Wall Thickness The method of process.

The object of the present invention is achieved like this, a kind of device for Complex Aluminum Alloy Casting with Thin Wall Thickness quenching, It is characterized in that including following five component parts：Base support, splash tube assembly, water tank, catch tray and protective cover, intelligence control System processed, base support centre weld a middle jet pipe and install tablet；Splash tube assembly is divided into outer splash tube assembly in Splash tube assembly；Catch tray is mainly used for collecting quenched medium, then controls back liquid water pump by liquid level valve and draw back medium To water tank；Protective cover is the baffle that can be opened and closed, and spraying and splashing facility is surrounded, aqueous splash everywhere when preventing from quenching.

Preferably, base support is generally circle, is welded by round steel.

Preferably, intelligence control system includes processing parameter setting module, ejection medium matching module, dynamic decoupling control Cooling procedure is established in system, medium control, nozzle and casting dynamic control part according to cooling medium size composition with quenching rate relationship In models for temperature field flow, temperature and concentration of medium etc. are controlled by the feedback of temperature signal.

Above-mentioned apparatus splash tube assembly design principle：Outer splash pipe is used for the splash of part outer surface, using 1 cun of galvanized pipe, According to casting appearance and size, according to the covered effective area of every nozzle, while the heavy wall boss on part is considered, every Solid nozzle is set on jet pipe, and outer nozzle is divided into the two groups of jet pipe groups in left and right, and every group is handed over by 3 long jet pipes and 3 short jet pipe respectively Mistake installation, every group is fixed on semi-circular holder, and every group of jet pipe hinge is on pedestal, the separable jet pipe group of composition activity, Facilitate picking and placeing for part, long jet pipe setting nozzle is several, and short spray section setting nozzle is several.Middle jet pipe is sprayed for accessory inner surface It splashes, using 2 cun of galvanized pipes, according to the area and length of inner surface, it is several that middle jet pipe axial direction is respectively set nozzle, every spray Solid nozzle is set on pipe, and every group of radially uniform distribution nozzles of nozzle are several.Middle jet pipe is adjusted highly on base support.

Above-mentioned apparatus nozzle can generate solid cone type spray shape, and inlet zone is rounded, spray angle 43 ° to 120 ° it Between it is adjustable.Such nozzle can generate under large-scale flow rate and pressure to be evenly distributed, waits until spray bigger than normal during droplet size is Mist, spraying can realize that the covering of the gross area in border circular areas, this uniform spray shapes distribution derive from its unique blade Design and big and unimpeded runner and excellent control characteristic.Meanwhile with the spherojoint of universal position adjustable, facilitating control The injection direction of nozzle processed.

Above-mentioned intelligence control system can realize that flow, temperature and the state of medium automatically control by the following method.Heat Galvanic couple constantly sends cooling temperature changing value to A/D by temperature transmitter, optical coupling isolator（Simulation/numerical value）Module, and Feed back to PLC（Controllable logic programmable device）Host.With PID（Proportional integral derivative adjuster）Instruction, by given temperature control After curve carries out PID arithmetic with thermocouple feedback signal, output control signal is through D/A（Numerical value/simulation）Analog quantity is converted to, is led to Optical coupling isolator, over-zero trigger are crossed as SCR（Silicon controlled rectifier (SCR)）Regulate signal, proportioning valve is then in D/A modules at this time The lower flow for changing medium of control, temperature control modules change in-furnace temperature under bidirectional triode thyristor control, and nozzle is then in medium Change the state of medium under control module, and then effectively controls casting cooling rate.

Above-mentioned each pipe-line system is provided with many valves, and the central processing unit of PLC can be real according to internal control program Now equipment startup, the flexible of each valve folding, rate-of flow and state are controlled, and indicated by the LED signal lamp of its output end The action completion status for exporting control, executes corresponding output driving, and record systematic parameter curve.

Above-mentioned apparatus passes through reasonable Arrangement nozzle location, the performance parameter of the cooling medium of regulation and control and different splash modes Deng making at casting heavy wall, at thin-walled and the different parts cooling rate such as reinforcing rib is uniform, obtain the premium casting deformed less.

Another object of the present invention is achieved in that a kind of making for Complex Aluminum Alloy Casting with Thin Wall Thickness quenching unit With method, it is characterised in that include the following steps：

The first step, to large-scale complex thin-wall aluminium in heat-treatment furnace of the heat treatment temperature precision controlling within the scope of ± 5 DEG C Alloy-steel casting carries out solution treatment, is heated to 535 ± 5 DEG C, keeps the temperature 12 ~ 14h；

Second step heats PAG Polymer quenching mediums to 35 ~ 40 DEG C in liquid reserve tank, will be dissolved by driving Casting afterwards is hung in splash cooling device, and transfer time controls within 15s；

Third walks, and opening splash cooling device by PLC control system carries out casting quenching treatment, and hydrojet water pump starts work Make, device starts hydrojet, and hydraulic pressure is up to 0.05 ~ 0.3MPa；

4th step, the temperature of thermocouple monitoring casting send temperature change value to A/D modules, by optical coupling isolator, Regulate signal of the over-zero trigger as SCR, the flow of medium is controlled by proportioning valve at any time, and liquid reserve tank controls the temperature of medium Degree, the state of Jet control medium；

5th step returns liquid water pump under the control of liquid level valve, quenched water will be collected in catch tray and is withdrawn into water tank, Until casting temperature is cooled to 80 ± 5 DEG C, 25 ~ 35s of duration；

6th step, quenching terminate, and PLC control system is automatically brought into operation electromagnet cut off valve arresting stop hydrojet, and casting is hung out.

The present invention has the advantages that：

1, apparatus of the present invention high degree of automation, main operational steps such as hydrojet, flow, temperature and the state control of medium System, medium return liquid, stop hydrojet process can be controlled by PLC quickly, be precisely accomplished, it is easy to operate；Main technological parameter is such as Casting temperature, medium temperature, hydraulic pressure, cooling rate can vividly be shown on the display apparatus, and output temperature curve and cooling Rate curve, convenient for analyzing quenching process.

The present apparatus can accurately control the flow of medium, temperature, state by PLC control system, according to casting different parts Dimensional thickness provides different cooling rates, is conducive to the Quick uniform cooling of casting, reduces the deflection of casting, ensure quenching Quality；

The present apparatus is furnished with back liquid water pump, and the hardening media collected in catch tray can be withdrawn into liquid reserve tank, makes entirely to spray It splashes process and is in a cyclic process, improve the utilization rate of hardening media, saved the investment of equipment；

Present apparatus liquid reserve tank is furnished with heating device, can guarantee that hardening media temperature in quenching process can be adjusted, passes through Hardening media temperature is controlled, the quenched precision of casting and performance are improved；

The protective cover of the present apparatus can surround spraying and splashing facility, aqueous splash everywhere when preventing from quenching, and ensure that quenching process is existing Field is clean, ensures the person, equipment safety；

The device continuity is strong, and work efficiency is high, avoids excessive time, goods and materials loss, application value is higher, work Industry has a high potential.

2, the casting under present invention process carries out quenching treatment, thermocouple moment in the splash cooling device that PLC is controlled It monitors casting temperature, feeds back to control system, accurately control the flow of medium, temperature, state, realize that the Quick uniform of casting is cold But, the quality that ensure that casting has reached quenching and has required, realized batch production, improve production efficiency.

For heavy complicated thin-walled aluminum alloy casting, casting dimension thin and thick position is different, and conventional quenching technique is difficult The uniform cooling for realizing casting different location, deflection is serious after causing casting to quench, and internal residual stress is also very big, or even meeting There is situations such as hardening crack.And this technique then can thoroughly solve the above problems, and obtain the premium casting that deformation is small, performance is good, solution It has determined and has perplexed the problem of quenching field for many years, served aerospace, automobile ship and national defence related field.

Description of the drawings

Fig. 1 is used for the splash quenching unit structural schematic diagram of Complex Aluminum Alloy Casting with Thin Wall Thickness；

In figure：1. 1 group of outer nozzle;Jet pipe in 2.;3. workpiece;4. thermocouple；5. 2 groups of outer nozzle;6. electricity Magnetic shut-off valve;7. pressure transmitter；8. proportioning valve;9. liquid level valve；10. catch tray；11. protective cover；12. returning liquid water pump； 13. hydrojet water pump；14. liquid reserve tank；15. signal amplifier；16.PLC control devices；

Fig. 2 chassis supporting stand structure schematic diagrames；

Nozzle component structural schematic diagram in Fig. 3；

Fig. 4 long outer nozzle component structure diagrams；

The short outer nozzle component structure diagrams of Fig. 5；

Fig. 6 liquid level valve control schematic diagrams；

In figure：When liquid level is in No. 1 position, liquid water pump is closed back；When liquid level is in No. 2 positions, liquid water is opened back Pump；

Fig. 7 protective cover schematic diagrames；

The cooling control system schematic diagram that Fig. 8 is programmed based on PLC.

Specific implementation mode

Embodiment, the present embodiment is using certain large complicated Al-alloy casing casting as application, specific profile size：It is high 750mm, small end justify Φ 286.5mm, big end rectangle 376.7mm × 413.4mm, main body wall thickness 2.9mm, the more boss in inner cavity, muscle, material Material：ZL114A.

Operating procedure is shown in invention content.

Main working parameters are as follows：535 ± 5 DEG C of casting solid solubility temperature；12 ~ 14h of soaking time；PAG water-soluble polymers 35 ~ 40 DEG C of heating temperature；Within casting transfer time 15s；0.05 ~ 0.3MPa of splash hydraulic pressure；25 ~ 35s of cool time.

Claims (1)

1. a kind of application method of Complex Aluminum Alloy Casting with Thin Wall Thickness quenching unit, which includes following five compositions Part：Base support, splash tube assembly, water tank, catch tray and protective cover, intelligence control system, base support centre The middle jet pipe of welding one installs tablet；Splash tube assembly is divided into outer splash tube assembly and middle splash tube assembly；Catch tray is mainly used In collecting quenched medium, liquid water pump is controlled back by liquid level valve, hardening media is withdrawn into water tank；Protective cover is to open The baffle for opening and closing, spraying and splashing facility is surrounded, aqueous splash everywhere when preventing from quenching；

Characterized by the following steps：

The first step, to large-scale complex thin-wall aluminium alloy in heat-treatment furnace of the heat treatment temperature precision controlling within the scope of ± 5 DEG C Casting carries out solution treatment, is heated to 535 ± 5 DEG C, keeps the temperature 12~14h；

Second step, heating PAG Polymer quenching mediums, will be after solid solution by driving to 35~40 DEG C in liquid reserve tank Casting is hung in splash cooling device, and transfer time controls within 15s；

Third walks, and opening splash cooling device by PLC control system carries out casting quenching treatment, and hydrojet water pump is started to work, Device starts hydrojet, and hydraulic pressure is up to 0.05~0.3MPa；

4th step, the temperature of thermocouple monitoring casting send temperature change value to A/D modules, pass through optical coupling isolator, zero passage Regulate signal of the trigger as SCR, the flow of medium is controlled by proportioning valve at any time, and liquid reserve tank controls the temperature of medium, spray Mouth controls the state of medium；

5th step returns liquid water pump under the control of liquid level valve, quenched water will be collected in catch tray and is withdrawn into water tank, until Casting temperature is cooled to 80 ± 5 DEG C, 25~35s of duration；

6th step, quenching terminate, and PLC control system is automatically brought into operation electromagnet cut off valve arresting stop hydrojet, and casting is hung out.