CN111036849A - Pouring system for controlling slag and purifying horizontally pouring gate and design method thereof - Google Patents
Pouring system for controlling slag and purifying horizontally pouring gate and design method thereof Download PDFInfo
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- CN111036849A CN111036849A CN201911211080.4A CN201911211080A CN111036849A CN 111036849 A CN111036849 A CN 111036849A CN 201911211080 A CN201911211080 A CN 201911211080A CN 111036849 A CN111036849 A CN 111036849A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/082—Sprues, pouring cups
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
- B22C9/086—Filters
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Abstract
The invention relates to the field of a pouring system in a casting process, in particular to a pouring system for controlling slag and purifying a cross gate and a design method thereof. 1) The design of more than two rows of cross runners is adopted, the cross runners are designed side by side, and the shape of the cross runners is circular, trapezoidal or rectangular; 2) the cross section areas of more than two rows of transverse runners are kept unchanged or gradually reduced, and the number of the transverse runners is 2-4; 3) the cross runners are connected with each other by adopting ingates at the lower parts of the side surfaces of the cross runners, and the ratio of the sum of the cross section areas of the ingates to the cross section area of the cross runners is (1-5): 1, the cross section area of a single ingate is 1/3-1 of that of a cross runner; 4) a filtering area is designed at the outlet of the cross gate, small-size impurities are controlled, the pouring speed is stabilized, and the metal liquid is prevented from splashing to generate scouring. Therefore, the problems that the conventional pouring system of a factory is unreasonable and the stable filling of molten metal, the purity and the like are difficult to ensure are solved.
Description
Technical Field
The invention relates to the field of a pouring system in a casting process, in particular to a pouring system for controlling slag and purifying transverse pouring gate and a design method thereof, which are generally suitable for the design of the pouring system for sand casting, metal mold casting, casting blank pouring and precision casting of nonferrous metals, ferrous metals, high-temperature alloys and the like.
Background
Conventional gating system designs are typically both closed (compressed) and open (uncompressed) approaches. The cross sections of a sprue, a cross runner and an ingate of the closed pouring system are gradually reduced, the flow speed of molten metal is too high, the turbulence is serious, and the casting mold is easily washed to cause air entrainment and inclusion defects (X-ray observation shows that the air entrainment and air entrainment defects are easily caused when the mold filling speed is more than 0.5 m/s). The cross sections of a sprue, a cross runner and an ingate of the open type pouring system are gradually enlarged, so that when molten metal is filled, a large air gap exists in the sprue, gas and the molten metal interact to form an oxide film, the gas and the oxide film are involved in the molten metal to form a crack and a loose source, and the casting is cracked and loosened.
Disclosure of Invention
Aiming at the problems in the prior art, the invention aims to provide a pouring system for controlling slag and purifying transverse pouring gate and a design method thereof, and solves the problems that the existing pouring system of a factory is unreasonable, and the stable filling of molten metal and the purity are difficult to ensure.
The technical scheme of the invention is as follows:
a pouring system for controlling slag and purifying transverse pouring gate specifically comprises the following structures: the sprue is of a conical structure with a large upper part and a small lower part, and the maximum cross-sectional area of the upper end is 1.5-3 times of the minimum cross-sectional area of the tail end; the cross gate is connected with the lower end of the straight gate through a smooth arc-shaped curve channel, the radius of the arc-shaped curve channel is 1-5 times of the equivalent diameter of the cross gate, the radius of the cross section of the arc-shaped curve channel is subjected to variable diameter design, and the variable diameter is changed to be 1-5 times of the equivalent radius of the cross section area of the cross gate; and more than two transition ingates are connected to the horizontal runner, and the sum of the cross-sectional areas of the transition ingates is 2-10 times of that of the horizontal runner.
In the pouring system with the cross runners controlled by slag and purified, the cross runners are two to four rows, the cross section areas of the first row of cross runners and the second row of cross runners are the same or the cross section areas of the second row of cross runners are sequentially reduced backwards, and the cross section area of the first row of cross runners is 1-3 times of the minimum cross section area of the tail end of the sprue; the cross-sectional area ratio of the first row of transverse runners to the second row of transverse runners to the third row of transverse runners to the fourth row of transverse runners is 1 (1-0.8) to 1-0.8; the cross runners more than two rows are in uniform shapes or different shapes, the cross runners are designed in parallel, and the distance between the cross runners is 1-3 times of the equivalent diameter of the cross section of the cross runner.
The pouring system for controlling the slag and purifying the cross runners is characterized in that filtering areas are respectively designed at the bottom outlets of the last row of cross runners, the number of the filtering areas is not less than 1, each filtering area is connected with the pouring system to an inner runner of a casting mold, and the cross section area of each filtering area is 0.5-1 time of that of the last row of cross runners.
The pouring system with the cross runners controlling and purifying the slag is characterized in that the distances between the first row of cross runners and the second row of cross runners, between the second row of cross runners and the third row of cross runners and between the third row of cross runners and the fourth row of cross runners are 10-200 mm.
In the pouring system with the cross pouring gate for controlling slag and purifying, the sprue is higher than the riser of the casting, so that the included angle between the connecting line of the center of the riser farthest from the casting and the upper end of the sprue and the horizontal line is controlled to be 5-45 degrees.
The design method of the pouring system for controlling slag and purifying the cross gate comprises the following steps:
1) the design of more than two rows of cross runners is adopted, the cross runners are designed side by side, and the shape of the cross runners is circular, trapezoidal or rectangular;
2) the cross section areas of more than two rows of transverse runners are kept unchanged or gradually reduced, and the number of the transverse runners is 2-4;
3) the cross runners are connected with each other by adopting transition ingates at the lower parts of the side surfaces of the cross runners, and the ratio of the sum of the cross section areas of the transition ingates to the cross section area of the cross runners is (1-5): 1, the cross section area of a single transition ingate is 1/3-1 of that of a cross runner;
4) a filtering area is designed at the outlet of the cross gate, small-size impurities are controlled, the pouring speed is stabilized, and the metal liquid is prevented from splashing to generate scouring.
The design method of the pouring system with the sprue for controlling slag and purifying the sprue is characterized in that the maximum mold filling time of molten metal is obtained by dividing the total weight of the poured molten metal by the minimum rising speed of the molten metal in a casting mold, and the minimum cross-sectional area of molten metal filling required by the whole pouring system is determined at the tail end of a sprue according to the flow equality principle and the maximum mold filling time.
According to the design method of the pouring system with the sprue for controlling slag and purifying the molten metal, the minimum rising speed of the molten metal in the casting mold is different according to the type of each casting mold, the maximum mold filling time of the casting mold to be poured is found, and the flow of the molten metal is obtained by combining the total volume of the molten metal, wherein the formula is as follows:
wherein: q is the molten metal flow rate in m3S, V: total volume of the poured molten metal in m3(ii) a t: the maximum filling time of the pouring molten metal is s; and after the flow of the molten metal is obtained, determining the minimum cross-sectional area of the tail end of the sprue required by different casting types.
According to the design method of the horizontal pouring gate slag-control pure-purification pouring system, the minimum cross-sectional area of the tail end of the straight pouring gate is obtained by the following formula: q is A2V2、
B1＝1.25+n10.25; wherein: q is the molten metal flow rate in m3/s，A2Is the area of the sprue end in m2；V2The molten metal speed at the end of the sprue is unit m/s; hPIs the average static head of the casting system in m; g is the acceleration of gravity; h is the total height of the sprue cup and the sprue molten metal, and the unit is m; b is1Is the energy loss factor of molten metal in the sprue, n1The number of bends of the sprue at 90 ℃ is shown, and h is the height of the molten metal in the sprue cup in m.
According to the design method of the pouring system with the cross pouring channel for slag control and pure purification, the maximum cross-sectional area of the top of the straight pouring channel is determined to be 1.5-3 times of the minimum cross-sectional area of the tail end according to the flow equality principle and the determined minimum cross-sectional area; the specific formula is as follows: a. the2V2＝A1V1、
Obtaining a maximum cross-sectional area of the sprue top, wherein: a. the1Is the maximum cross-sectional area at the top of the sprue, in m2；V1The molten metal velocity at the inlet of the top of the sprue is in m/s; g is gravity acceleration, 9.8m2S; h is the height of the metal liquid in the pouring cup in m.
The invention has the following advantages and beneficial effects:
1) the invention adopts a design of a plurality of rows of cross runners, the cross runners are designed side by side, the cross runners can be round, trapezoidal, rectangular and the like, and the purpose is to filter large-scale impurities and coiled slag through a plurality of rows of cross runners, so that gas floats upwards into the cross runners.
2) The cross section area of the multi-row transverse pouring channels is kept unchanged or gradually reduced, and the purpose is to prevent slag entrapment and large-size impurities from entering the downstream.
3) The bottom of the horizontal pouring channel is connected with the bottom of the horizontal pouring channel by adopting a transition inner pouring channel, and the ratio of the sum of the cross-sectional areas of the transition inner pouring channel to the cross-sectional area of the horizontal pouring channel is (1-5): 1, the cross sectional area of single transition ingate is 1/3 ~ 1 of cross sectional area, waters the aim at with inclusion float to the cross top, avoids inclusion, roll up the sediment and during gaseous entering foundry goods.
4) According to the invention, the filtering area is designed at the outlet of the transverse pouring channel, so that small-size impurities are controlled, the pouring speed is stabilized, and the metal liquid is prevented from splashing to generate scouring.
Drawings
FIG. 1 is a schematic view of the connection structure of the sprue and the runner according to the present invention.
FIGS. 2(a) - (b) are schematic views of the connection of two parallel rows of runners and the filtration zone with the transition gates of the present invention; fig. 2(a) is a front view, and fig. 2(b) is a plan view.
FIGS. 3(a) - (b) are schematic views of the connection of three parallel rows of runners and the filter area with the transition gates of the present invention; fig. 3(a) is a front view, and fig. 3(b) is a plan view.
FIGS. 4(a) - (b) are schematic views of the connection of four parallel rows of runners and the filter area with the transition gates of the present invention; fig. 4(a) is a front view, and fig. 4(b) is a plan view.
Fig. 5 is a schematic view of a machine tool body casting and a pouring system in embodiment 1.
Fig. 6 is a schematic view of a machine tool body casting and a pouring system in embodiment 2.
Wherein, 1, a straight pouring channel; 2, arc bend; 3, a horizontal pouring channel; 3-1, a first row of transverse runners; 3-2 second row of transverse runners; 3-3 third row of transverse runners; 3-4 fourth row of transverse pouring channels; 4, transition ingate; 5 a filtration zone; 6 gating the system to the ingate of the mold.
Detailed Description
In the specific implementation process, the design method of the pouring system for effectively controlling the air entrainment and the slag entrainment comprises the following steps:
obtaining the maximum mold filling time of the molten metal according to the total weight of the poured molten metal divided by the minimum rising speed of the molten metal in the casting mold, and determining the minimum cross-sectional area of the molten metal filling required by the whole pouring system at the tail end of the sprue according to the flow equality principle and the maximum mold filling time;
the minimum speed of the metal liquid level rising in the casting mold is obtained by searching documents in the technical field according to the difference of each casting mold type, the flow rate of the metal liquid is obtained by combining the total volume of the metal liquid according to the maximum mold filling time of the casting mold required to be poured, and the formula is as follows:
wherein: q is the molten metal flow rate in m3S, V: total volume of the poured molten metal in m3(ii) a t: the maximum filling time of the pouring molten metal is s. After the metal flow is obtained, the minimum cross-sectional area of the sprue end required by different mold types can be determined.
The minimum cross-sectional area of the sprue end is given by the following equation: q is A2V2、
B1＝1.25+n10.25; wherein: q is the molten metal flow rate in m3/s，A2Is the area of the sprue end in m2；V2The molten metal speed at the end of the sprue is unit m/s; hPIs the average static head of the casting system in m; g is the acceleration of gravity; h is the total height of the sprue cup and the sprue molten metal, and the unit is m; b is1Is the energy loss factor of molten metal in the sprue, n1The number of bends of the sprue at 90 ℃ is shown, and h is the height of the molten metal in the sprue cup in m.
According to the flow equality principle and the determined minimum cross-sectional area, determining that the maximum cross-sectional area of the top of the sprue is 1.5-3 times of the minimum cross-sectional area of the tail end; the specific formula is as follows: a. the2V2＝A1V1、
The maximum cross-sectional area of the sprue top is available, wherein: a. the1Is the maximum cross-sectional area at the top of the sprue, in m2；V1The molten metal velocity at the inlet of the top of the sprue is in m/s; g is gravity acceleration, 9.8m2S; h is the height of the metal liquid in the pouring cup, and the unit m is;
determining the cross-sectional area of the horizontal pouring gate to be 1-3 times of the minimum cross-sectional area of the tail end of the straight pouring gate according to the minimum cross-sectional area of the tail end of the straight pouring gate;
according to a negative pressure area generated by molten metal at the joint of a sprue 1 and a runner 3, when the design is right-angled, negative pressure is generated at a corner to cause gas entrainment, according to the generated negative pressure, the design of the size of an arc radius and the size of a variable diameter of a cross section area is analyzed and calculated according to hydromechanics, a smooth arc bend 2 is adopted at the joint of the sprue 1 and the runner 3, the radius of the arc bend 2 is 1-5 times of the equivalent diameter of the runner 3, the variable diameter design is carried out on the radius of the cross section of the arc bend 2, and the radius change is 1-5 times of the equivalent radius of the cross section area of the runner; and (4) performing a negative pressure test, wherein when the molten metal enters the area, the phenomenon of air entrainment does not exist, which indicates that the generated negative pressure is very small.
And designing more than two ingates according to the condition that the sum of the cross section areas of the ingates is 2-10 times of that of the cross runners, wherein the number of the ingates is determined according to the size of the cross section area and the type of the casting mold.
The design method can also design the cross runners into two parallel cross runners of a first row of cross runners 3-1 and a second row of cross runners 3-2 or a third row of cross runners 3-3 and a fourth row of cross runners 3-4. The cross section area of the first row of cross runners 3-1 is the same as that of the second row of cross runners 3-2 or the cross section area of the second row of cross runners is sequentially reduced backwards, and the cross section area of the first row of cross runners 3-1 is 1-3 times of the minimum cross section area of the tail end of the sprue; the cross-sectional area ratio of the first row of cross runners 3-1 to the second row of cross runners 3-2 to the third row of cross runners 3-3 to the fourth row of cross runners 3-4 is 1 (1-0.8) to (1-0.8). The distances between the first row of cross runners 3-1 and the second row of cross runners 3-2, between the second row of cross runners 3-2 and the third row of cross runners 3-3 and between the third row of cross runners 3-3 and the fourth row of cross runners 3-4 are 10-200 mm.
The sprue 1 is higher than the riser of the casting, so that the included angle between the connecting line of the center of the riser farthest away from the casting and the upper end of the sprue 1 and the horizontal line is controlled to be 5-45 degrees.
As shown in fig. 1, the pouring system designed according to the above method for effectively controlling the entrainment of gas and the entrainment of slag has the following specific structure:
the sprue 1 is of a conical structure with a large upper part and a small lower part, the maximum cross section area of the upper end is 1.5-3 times of the minimum cross section area of the tail end, and the design with the large upper part and the small lower part is beneficial to gas and inclusion to float to the top, and meanwhile, the sprue 1 can be prevented from being washed away by molten metal; the cross gate 3 is connected with the lower end of the straight gate 1 through a smooth arc bend 2(a transition section is connected with the cross gate) and the radius of the arc bend 2 is 1-5 times of the equivalent diameter of the cross gate 3, the radius of the cross section of the arc bend 2 is designed to be variable in diameter, and the variable diameter is changed to be 1-5 times of the equivalent radius of the cross section (section) area of the cross gate; the cross gate 3 is connected with more than two transition ingates 4, and the sum of the cross section (section) areas of the transition ingates 4 is 2-10 times of the cross section area of the cross gate 3.
As shown in fig. 2(a) - (b), the runners are two parallel runners, namely a first row of runner 3-1 and a second row of runner 3-2, the cross-sectional areas of the first row of runner 3-1 and the second row of runner 3-2 are different, the second row of runner 3-2 is 0.85 times of the first row of runner 3-1, the cross-sectional area of the first row of runner 3-1 is 1-3 times of the minimum cross-sectional area of the tail end of the runner, the distance between the first row of runner 3-1 and the second row of runner 3-2 is 10-200 mm, and the two parallel runners are beneficial to controlling stable filling of molten metal, so that the molten metal is constantly in a filling state in a pouring system, and cracks and pore defects caused by gas and oxide film involved in the molten metal are prevented.
More than two transition ingates 4 are arranged between the first row of cross runners 3-1 and the second row of cross runners 3-2, the transition ingates 4 are of a scarf structure, the sum of the cross section areas of the transition ingates is 2-10 times of that of the first row of cross runners 3-1, the maximum thickness of the transition ingates is 10-20 mm, and the slag blocking technology between the two parallel cross runners prevents slag and foreign impurities in molten metal from entering castings, so that slag holes and foreign impurities exceed standards, the purity and the molten metal flow of the molten metal are guaranteed, and the molten metal is prevented from splashing in a casting cavity.
And (3) respectively designing filtering areas 5 at the bottom outlets of the second row of cross runners 3-2, wherein the number of the filtering areas 5 is not less than 1, and each filtering area 5 is connected with a pouring system to an ingate 6 of the casting mold. The cross section area of the filtering area 5 is 0.5-1 times of the cross section area of the second row of cross runners 3-2, and the filtering area 5 mainly aims to control small-size impurities and stabilize the pouring speed and prevent molten metal from splashing to generate scouring.
As shown in FIGS. 3(a) - (b), the cross runners are a first row of cross runners 3-1, a second row of cross runners 3-2 and a third row of cross runners 3-3 which are parallel, the cross sectional areas of the first row of cross runners 3-1, the second row of cross runners 3-2 and the third row of cross runners 3-3 are different, the cross sectional area of the third row of cross runners 3-3 is 0.85 times that of the second row of cross runners 3-2, the cross sectional area of the second row of cross runners 3-2 is 0.85 times that of the first row of cross runners 3-1, the cross sectional area of the first row of cross runners 3-1 is 1-3 times that of the minimum cross sectional area of the tail end of the straight runner, the distance between the first row of cross runners 3-1 and the second row of cross runners 3-2 is 10-200 mm, the distance between the second row of cross runners 3-2 and the third cross runners 3-3 is 10-200 mm, the parallel transverse pouring channels are beneficial to controlling the stability of metal liquid filling, so that the metal liquid is constantly in a full-filling state in a pouring system, and cracks and pore defects caused by the fact that gas and an oxidation film are involved in the metal liquid are prevented.
More than two transition ingates 4 are arranged between the first row of cross runners 3-1 and the second row of cross runners 3-2, the transition ingates 4 are of a scarf structure, the sum of the cross section areas of the transition ingates 4 is 2-10 times of that of the first row of cross runners 3-1, and the maximum thickness of the transition ingates is 10-20 mm; more than two transition ingates 4 are arranged between the second row of cross runners 3-2 and the third row of cross runners 3-3, the transition ingates 4 are of a scarf structure, the sum of the cross section areas of the transition ingates 4 is 2-10 times of the cross section of the second row of cross runners 3-2, and the maximum thickness of the transition ingates is 10-20 mm; the slag blocking technology between the parallel transverse pouring channels prevents slag and foreign impurities in molten metal from entering a casting to cause that slag holes and foreign impurities exceed standards, ensures the purity of the molten metal and the flow of the molten metal, and simultaneously avoids the molten metal from splashing in a casting cavity.
And (3) respectively designing filtering areas 5 at the bottom outlets of the third row of cross runners 3-3, wherein the number of the filtering areas 5 is not less than 1, and each filtering area 5 is connected with a pouring system to an ingate 6 of the casting mold. The cross section area of the filtering area 5 is 0.5-1 times of the cross section area of the third row of cross runners 3-3, and the filtering area 5 mainly aims to control small-size impurities and stabilize the pouring speed and prevent molten metal from splashing to generate scouring.
As shown in FIGS. 4(a) - (b), the runners are parallel runners of a first row of runners 3-1, a second row of runners 3-2, a third row of runners 3-3 and a fourth row of runners 3-4, the cross-sectional areas of the first row of runners 3-1, the second row of runners 3-2, the third row of runners 3-3 and the fourth row of runners 3-4 are different, the fourth row of runners 3-4 is 0.85 times of the third row of runners 3-3, the third row of runners 3-3 is 0.85 times of the second row of runners 3-2, the second row of runners 3-2 is 0.85 times of the first row of runners 3-1, the cross-sectional area of the first row of runners 3-1 is 1-3 times of the minimum cross-sectional area of the tail end of the sprue, the distance between the first row of runners 3-1 and the second row of runners 3-2 is 10-200 mm, the distance between the second row of cross runners 3-2 and the third row of cross runners 3-3 is 10-200 mm, the distance between the third row of cross runners 3-3 and the fourth row of cross runners 3-4 is 10-200 mm, and the parallel cross runners are beneficial to controlling the molten metal to be stably filled, so that the molten metal is constantly in a filling state in a pouring system, and gas and an oxidation film are prevented from being involved in the molten metal to cause cracks and pore defects.
More than two transition ingates 4 are arranged between the first row of cross runners 3-1 and the second row of cross runners 3-2, the transition ingates 4 are of a scarf structure, the sum of the cross section areas of the transition ingates 4 is 2-10 times of that of the first row of cross runners 3-1, and the maximum thickness of the transition ingates is 10-20 mm; more than two transition ingates 4 are arranged between the second row of cross runners 3-2 and the third row of cross runners 3-3, the transition ingates 4 are of a scarf structure, the sum of the cross section areas of the transition ingates 4 is 2-10 times of the cross section of the second row of cross runners 3-2, and the maximum thickness of the transition ingates is 10-20 mm; more than two transition ingates 4 are arranged between the third row of cross runners 3-3 and the fourth row of cross runners 3-4, the transition ingates 4 are of a scarf structure, the sum of the cross section areas of the transition ingates 4 is 2-10 times of the cross section of the third row of cross runners 3-3, and the maximum thickness of the transition ingates is 10-20 mm; the slag blocking technology between the parallel transverse pouring channels prevents slag and foreign impurities in molten metal from entering a casting to cause that slag holes and foreign impurities exceed standards, ensures the purity of the molten metal and the flow of the molten metal, and simultaneously avoids the molten metal from splashing in a casting cavity.
And (3) respectively designing filtering areas 5 at the bottom outlets of the fourth row of cross runners 3-4, wherein the number of the filtering areas 5 is not less than 1, and each filtering area 5 is connected with a pouring system to an ingate 6 of the casting mold. The cross section area of the filtering area 5 is 0.5-1 times of the cross section area of the fourth row of cross runners 3-4, and the filtering area 5 mainly aims to control small-size impurities and stabilize the pouring speed and prevent molten metal from splashing to generate scouring.
In the present invention, "equivalent diameter" or "equivalent radius" means the diameter or radius of a circle equal to the cross-sectional area or the inner gate cross-sectional area of the runner.
The present invention will be described in further detail below with reference to examples.
Example 1
Pouring is carried out on a lathe body of a certain type of machine tool, a pouring material HT250 is adopted, the pouring temperature is 1360 ℃, the weight of a casting is 10t, a pouring system is designed to be that a sprue 1 is designed into a conical shape, the top end of the sprue is phi 90mm, the minimum cross-sectional area of the tail end of the sprue is phi 55mm, the height of the sprue 1 is 1650mm, the design principle of the sprue is the flow equality principle, the design of the upper part and the lower part is beneficial to gas and mixed with floating to the top, and meanwhile, the scouring of metal liquid to the sprue can be avoided.
As shown in figures 3 and 5, the corners of the sprue 1 and the first row of runners 3-1 are transited by the arc-shaped bend 2, the radius of the arc-shaped bend 2 is 80mm, the equivalent diameter of the first row of runners 3-1 is 60mm, the cross section area of the arc-shaped bend 2 is subjected to reducing design, the diameter is changed between 55mm and 90mm, and the phenomenon that the air entrainment is caused by negative pressure generated at the corners is avoided, so that the difference of the invention in comparison with the prior art can be seen.
By utilizing the parallel design of three transverse runners, the cross sectional areas of a first row of transverse runners 3-1 and a second row of transverse runners 3-2 are different, the cross sectional areas of a third row of transverse runners 3-3 and a second row of transverse runners 3-2 are different, the equivalent diameter of the cross section of the first row of transverse runners 3-1 is 60mm, the equivalent diameter of the cross section of the second row of transverse runners 3-2 is 54mm, the equivalent diameter of the cross section of the third row of transverse runners 3-3 is 50mm, the distance between the second row of transverse runners 3-2 and the first row of transverse runners 3-1 is 50mm, the distance between the second row of transverse runners 3-2 and the third row of transverse runners 3-3 is 50mm, the parallel transverse runners are favorable for controlling the stable filling of molten metal, and the molten metal is constantly in a filling state in a pouring system.
The transition ingate 4 is designed in large size, the transition ingate can be set to 3 channels, and the sum of the cross-sectional areas of the transition ingates is 230mm2As shown in fig. 5, no gas and oxide film are involved in the molten metal during the pouring process in this embodiment, and no cracks and air holes are caused. During pouring, no metal liquid splashes in the casting cavity.
Through the design parameters of the gating system, the design of the gating system is reasonable through simulation verification through computer simulation.
Example 2
Pouring is carried out on a lathe body of a certain type of machine tool, a pouring material HT250 is adopted, the pouring temperature is 1370 ℃, the weight of a casting is 5t, a pouring system is designed to be that a sprue 1 is designed to be a conical type, the top end of the sprue is phi 75mm, the tail end of the sprue 1 is phi 50mm, the height of the sprue 1 is 1000mm, the design principle of the sprue is the flow equality principle, the design of the upper part and the lower part is beneficial to gas, the top is floated in a mixed mode, and meanwhile the metal liquid can be prevented from scouring the sprue 1.
As shown in figures 2 and 6, the corners of the sprue 1 and the first row of runners 3-1 are transited by the arc-shaped bend 2, the radius of the arc-shaped bend 2 is 80mm, the equivalent diameter of the first row of runners 3-1 is 60mm, the cross section area of the arc-shaped bend 2 is subjected to reducing design, the diameter is changed between 55mm and 90mm, and the phenomenon that the air entrainment is caused by negative pressure generated at the corners is avoided, so that the difference of the invention in comparison with the prior art can be seen.
By utilizing the parallel design of the two cross runners, the cross section areas of the first row of cross runners 3-1 and the second row of cross runners 3-2 are different, the equivalent diameter of the cross section of the first row of cross runners 3-1 is 60mm, the equivalent diameter of the cross section of the second row of cross runners 3-2 is 54mm, the distance between the second row of cross runners 3-2 and the first row of cross runners 3-1 is 50mm, the parallel cross runners are favorable for controlling the stability of molten metal filling, and the molten metal is in a filling state in a pouring system at all times.
The working process and the result of the invention are as follows:
according to the invention, the minimum cross section area of the molten metal filling type required by the whole pouring system is designed at the tail end of the sprue, and the stability of the molten metal filling type is controlled by utilizing the design of the two parallel cross runners, so that the molten metal is constantly in a filling state in the pouring system, and gas and an oxidation film are prevented from being involved in the molten metal to cause cracks and pore defects; slag removal technologies such as slag resistance design and the like between two parallel transverse pouring channels are utilized to prevent slag and foreign impurities in molten metal from entering castings to cause the standard exceeding of slag holes and foreign impurities; the corners of the straight pouring channel and the cross pouring channel are in arc transition, the radius change is 2-3 times of the equivalent radius of the cross section area of the cross pouring channel, air entrainment caused by negative pressure generated at the corners is avoided, and the purity of molten metal is ensured; the design technology of the large size of the ingate ensures the flow of molten metal and avoids the molten metal from splashing in the cavity of the casting.
The embodiment results show that the invention designs a pouring system for effectively controlling the coiling gas and the coiling slag, and the minimum cross section area design at the tail end of the sprue is used for ensuring the mold filling time of molten metal; the metal liquid is ensured to be fully filled in the pouring system by utilizing the design of two parallel transverse pouring channels and arc transition; the slag control technology ensures that the inclusion and the slag entrapment in the molten metal do not enter the casting cavity. The design of the pouring system avoids secondary oxidation, gas entrainment and slag entrainment generated in the pouring process of the molten metal, and ensures the purity of the molten metal and the quality of castings.
Claims (10)
1. The utility model provides a runner accuse sediment purifyingly system of pouring which characterized in that, concrete structure as follows: the sprue is of a conical structure with a large upper part and a small lower part, and the maximum cross-sectional area of the upper end is 1.5-3 times of the minimum cross-sectional area of the tail end; the cross gate is connected with the lower end of the straight gate through a smooth arc-shaped curve channel, the radius of the arc-shaped curve channel is 1-5 times of the equivalent diameter of the cross gate, the radius of the cross section of the arc-shaped curve channel is subjected to variable diameter design, and the variable diameter is changed to be 1-5 times of the equivalent radius of the cross section area of the cross gate; and more than two transition ingates are connected to the horizontal runner, and the sum of the cross-sectional areas of the transition ingates is 2-10 times of that of the horizontal runner.
2. The runner slag-control pure-purification pouring system according to claim 1, wherein the runners are in two to four rows, the cross-sectional areas of the first row of runners and the second row of runners are the same or the cross-sectional areas of the second row of runners are sequentially reduced, and the cross-sectional area of the first row of runners is 1-3 times of the minimum cross-sectional area of the tail end of the sprue; the cross-sectional area ratio of the first row of transverse runners to the second row of transverse runners to the third row of transverse runners to the fourth row of transverse runners is 1 (1-0.8) to 1-0.8; the cross runners more than two rows are in uniform shapes or different shapes, the cross runners are designed in parallel, and the distance between the cross runners is 1-3 times of the equivalent diameter of the cross section of the cross runner.
3. The runner slag-control pure-purification pouring system according to claim 2, wherein the bottom outlets of the last row of runners are respectively provided with filtering areas, the number of the filtering areas is not less than 1, each filtering area is used for connecting the pouring system to an inner runner of a casting mold, and the cross-sectional area of each filtering area is 0.5-1 times that of the last row of runners.
4. The runner slag-control pure-purification pouring system according to claim 2, wherein the distance between the first row of runners and the second row of runners, between the second row of runners and the third row of runners, and between the third row of runners and the fourth row of runners is 10-200 mm.
5. The runner slag-control pure-purification pouring system according to claim 1, wherein the sprue is higher than the riser of the casting, so that the included angle between the connecting line of the center of the riser farthest from the casting and the upper end of the sprue and the horizontal line is controlled to be 5-45 degrees.
6. A method for designing a runner slag-controlling and purifying gating system according to any one of claims 1 to 5, characterized by comprising the steps of:
1) the design of more than two rows of cross runners is adopted, the cross runners are designed side by side, and the shape of the cross runners is circular, trapezoidal or rectangular;
2) the cross section areas of more than two rows of transverse runners are kept unchanged or gradually reduced, and the number of the transverse runners is 2-4;
3) the cross runners are connected with each other by adopting transition ingates at the lower parts of the side surfaces of the cross runners, and the ratio of the sum of the cross section areas of the transition ingates to the cross section area of the cross runners is (1-5): 1, the cross section area of a single transition ingate is 1/3-1 of that of a cross runner;
4) a filtering area is designed at the outlet of the cross gate, small-size impurities are controlled, the pouring speed is stabilized, and the metal liquid is prevented from splashing to generate scouring.
7. The method for designing a runner gating system with controlled slag and purified purification according to claim 6, wherein the maximum filling time of the molten metal is obtained by dividing the total weight of the poured molten metal by the minimum rising speed of the molten metal level in the mold, and the minimum cross-sectional area of the molten metal filling required for the whole gating system is determined at the end of the sprue according to the flow equality principle and the maximum filling time.
8. The method for designing a runner slag-controlling and purifying gating system according to claim 7, wherein the minimum speed of the metal level rise in the casting mold is determined according to the type of each casting mold, and the flow rate of the metal is obtained by finding the maximum filling time of the casting mold to be poured and combining the total volume of the metal, and the formula is as follows:
wherein: q is the molten metal flow rate in m3S, V: total volume of the poured molten metal in m3(ii) a t: the maximum filling time of the pouring molten metal is s; and after the flow of the molten metal is obtained, determining the minimum cross-sectional area of the tail end of the sprue required by different casting types.
9. The method of designing a runner slag-controlling pur-fied gating system according to claim 8, wherein the minimum cross-sectional area of the sprue end is obtained by the following formula: q is A2V2、
B1＝1.25+n10.25; wherein: q is the molten metal flow rate in m3/s，A2Is the area of the sprue end in m2；V2The molten metal speed at the end of the sprue is unit m/s; hPFor average static head of the casting systemA bit m; g is the acceleration of gravity; h is the total height of the sprue cup and the sprue molten metal, and the unit is m; b is1Is the energy loss factor of molten metal in the sprue, n1The number of bends of the sprue at 90 ℃ is shown, and h is the height of the molten metal in the sprue cup in m.
10. The design method of the runner slag-control pure-purification pouring system according to claim 9, characterized in that according to the flow equality principle and the determined minimum cross-sectional area, the maximum cross-sectional area of the top of the sprue is determined to be 1.5-3 times of the minimum cross-sectional area of the tail end; the specific formula is as follows: a. the2V2＝A1V1、
Obtaining a maximum cross-sectional area of the sprue top, wherein: a. the1Is the maximum cross-sectional area at the top of the sprue, in m2；V1The molten metal velocity at the inlet of the top of the sprue is in m/s; g is gravity acceleration, 9.8m2S; h is the height of the metal liquid in the pouring cup in m.
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| CN113020547A (en) * | 2021-02-23 | 2021-06-25 | 共享铸钢有限公司 | Casting process of rotating wheel with shaft |
| RU2815519C1 (en) * | 2023-06-20 | 2024-03-18 | Акционерное общество Алтайского вагоностроения (АО "Алтайвагон") | Gating system and method of casting using it |
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Application publication date: 20200421 |