CN112605338A - Method for producing mounting seat steel casting based on precoated sand shell mold process - Google Patents
Method for producing mounting seat steel casting based on precoated sand shell mold process Download PDFInfo
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- CN112605338A CN112605338A CN202011310356.7A CN202011310356A CN112605338A CN 112605338 A CN112605338 A CN 112605338A CN 202011310356 A CN202011310356 A CN 202011310356A CN 112605338 A CN112605338 A CN 112605338A
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- 238000005266 casting Methods 0.000 title claims abstract description 93
- 239000004576 sand Substances 0.000 title claims abstract description 71
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 27
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 24
- 238000000034 method Methods 0.000 title claims abstract description 24
- 239000010959 steel Substances 0.000 title claims abstract description 24
- 230000008569 process Effects 0.000 title claims abstract description 23
- 238000007689 inspection Methods 0.000 claims abstract description 27
- 238000003754 machining Methods 0.000 claims abstract description 23
- 238000010438 heat treatment Methods 0.000 claims abstract description 14
- 239000006247 magnetic powder Substances 0.000 claims abstract description 13
- 238000003466 welding Methods 0.000 claims abstract description 13
- 230000007547 defect Effects 0.000 claims abstract description 12
- 238000000465 moulding Methods 0.000 claims abstract description 9
- 238000003723 Smelting Methods 0.000 claims abstract description 7
- 238000005520 cutting process Methods 0.000 claims abstract description 7
- 238000010791 quenching Methods 0.000 claims abstract description 7
- 230000000171 quenching effect Effects 0.000 claims abstract description 7
- 238000005496 tempering Methods 0.000 claims abstract description 7
- 238000001514 detection method Methods 0.000 claims abstract description 5
- 230000008439 repair process Effects 0.000 claims abstract description 4
- 239000011248 coating agent Substances 0.000 claims description 16
- 238000000576 coating method Methods 0.000 claims description 16
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 14
- 239000000843 powder Substances 0.000 claims description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 9
- 229910052845 zircon Inorganic materials 0.000 claims description 9
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 9
- 229910001208 Crucible steel Inorganic materials 0.000 claims description 8
- 238000001035 drying Methods 0.000 claims description 8
- 235000019353 potassium silicate Nutrition 0.000 claims description 7
- 238000001816 cooling Methods 0.000 claims description 6
- 150000002148 esters Chemical class 0.000 claims description 6
- 239000007789 gas Substances 0.000 claims description 6
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 6
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 3
- 244000035744 Hura crepitans Species 0.000 claims description 3
- 238000005452 bending Methods 0.000 claims description 3
- 238000005422 blasting Methods 0.000 claims description 3
- 238000003618 dip coating Methods 0.000 claims description 3
- 230000006698 induction Effects 0.000 claims description 3
- 239000006249 magnetic particle Substances 0.000 claims description 3
- 239000003345 natural gas Substances 0.000 claims description 3
- 238000005498 polishing Methods 0.000 claims description 3
- 238000004321 preservation Methods 0.000 claims description 3
- 230000009467 reduction Effects 0.000 claims description 3
- 238000004140 cleaning Methods 0.000 abstract description 5
- 238000005406 washing Methods 0.000 abstract description 3
- 239000004115 Sodium Silicate Substances 0.000 description 7
- 229910052911 sodium silicate Inorganic materials 0.000 description 7
- 229920005989 resin Polymers 0.000 description 5
- 239000011347 resin Substances 0.000 description 5
- 239000003110 molding sand Substances 0.000 description 4
- YLQBMQCUIZJEEH-UHFFFAOYSA-N Furan Chemical compound C=1C=COC=1 YLQBMQCUIZJEEH-UHFFFAOYSA-N 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- 230000003746 surface roughness Effects 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 238000003915 air pollution Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 231100000206 health hazard Toxicity 0.000 description 1
- 239000002085 irritant Substances 0.000 description 1
- 231100000021 irritant Toxicity 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- 150000002895 organic esters Chemical class 0.000 description 1
- 230000008520 organization Effects 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920001568 phenolic resin Polymers 0.000 description 1
- 238000002407 reforming Methods 0.000 description 1
- 230000008929 regeneration Effects 0.000 description 1
- 238000011069 regeneration method Methods 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 239000002341 toxic gas Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D31/00—Cutting-off surplus material, e.g. gates; Cleaning and working on castings
- B22D31/002—Cleaning, working on castings
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Mold Materials And Core Materials (AREA)
Abstract
The invention relates to a method for producing a mounting seat steel casting based on a precoated sand shell mold process, which adopts upper and lower box molding and comprises the following steps: (1) manufacturing a precoated sand core, (2) molding, (3) core dropping, mould assembling, (4) smelting and pouring, (5) unpacking and sand dropping, (6) cutting a casting head, (7) normalizing heat treatment, (8) rough machining, (9) flaw detection, welding repair, grinding, (10) quenching and tempering heat treatment, (11) magnetic powder flaw detection, appearance inspection and (12) finish machining. The core making process is simplified, the production efficiency can be improved by 20%, the product size precision is high, the machining allowance can be properly reduced by 4-8 mm, and the machining working hours of the casting can be reduced to a certain extent; the casting is formed by a precoated sand shell mold and a shell core, so that casting defects such as casting air holes, sand washing, sand inclusion, sand adhesion, cracks and the like are effectively prevented, and the qualified rate of the casting is improved by more than 30%; the precoated sand has excellent collapsibility, greatly reduces the sand cleaning difficulty and workload of the casting, and improves the casting cleaning production efficiency.
Description
Technical Field
The invention relates to a method for producing a mounting seat steel casting, in particular to a method for producing the mounting seat steel casting based on a precoated sand shell mold process.
Background
At present, three molding sand processes are mainly used in the production of steel castings in China: common CO2The method comprises a water glass sand hardening process, an ester hardening water glass sand process and a resin sand process, wherein the resin sand comprises alkali phenolic, pep-set, furan and bunny resin sand processes.
Common CO2The hardening sodium silicate-bonded sand process has the following problems: the used sand is extremely poor in collapsibility and difficult to regenerate and reuse, a large amount of waste sand is discharged to cause a serious environmental pollution problem, the appearance quality of a casting is poor, an enterprise adopting the process is difficult to control through the casting industry, and the process is about to be eliminated.
The problem of the ester hardening sodium silicate sand process is that: modified water glass of current cast steel enterprise's universal adoption, the selection of its modifier all has some problems with content, water glass can not reach the modified purpose of ideal, so water glass addition can not get down, the used sand regeneration index is poor, the reuse rate is low, still often appear in the production that the low creep of molding sand intensity sinks, defects such as the foundry goods normal air pocket appear, these all bring many troubles for the production organization, lead to some cast steel enterprises to have the worry to this technology when reforming transform the upgrading always, dare not adopt with the trade.
The problems of the resin sand process are as follows: firstly, for a steel casting with uneven wall thickness and a complex structure, the steel casting still has a crack tendency; secondly, the alkali phenolic resin film has good toughness, the used sand is difficult to regenerate, and the reuse rate can only reach about 75 percent; thirdly, irritant and toxic gas is emitted, so that the problems of human health hazard and air pollution are caused; fourthly, the price fluctuation of the resin is large, and the molding sand cost is high.
At present, the traditional method for producing the mounting seat steel casting adopts an ester hardening sodium silicate sand process. The process adopts upper and lower box molding, the outer mold and the sand core are both made of sodium silicate sand, and the outer mold and the sand core are dropped, closed and cast after entering the surface drying furnace for surface drying. In the actual production process, the influence of the environment factors on the sodium silicate sand is large, the addition of the sodium silicate and the organic ester is difficult to control, the sand mold is easy to absorb moisture, and creep deformation is generated to cause casting defects such as casting air holes and the like, so that the dimensional precision of the casting is influenced. Meanwhile, the deformability of the sodium silicate sand mold is poor, the surface has more scattered sand, the cavity of the casting has more crack defects, the problems of sand sticking, sand washing and sand inclusion of the casting are serious, the collapsibility of the molding sand is poor, and the difficulty in cleaning the casting is increased.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: in order to overcome the defects in the prior art, the method for producing the mounting seat steel casting based on the precoated sand shell mold process is provided.
The technical scheme adopted by the invention is as follows: a method for producing a mounting seat steel casting based on a precoated sand shell mold process adopts upper and lower box molding and comprises the following steps,
(1) manufacturing a precoated sand mold core: manufacturing a precoated sand shell mold and a shell core by using a core shooter, wherein the thickness of the shell mold and the shell core is 12-16 mm, coating the precoated sand shell mold and the shell core with water-based zircon powder coating by using common cast steel, and placing the precoated sand shell mold and the shell core into a surface drying furnace for surface drying after dip coating;
(2) modeling: putting the coated sand shell mold obtained in the step (1) into a lower box for molding, wherein the first mold is four, and the sand box is filled with ester hardened water glass sand; the upper box is provided with a refractory pipe and risers, and each 6 risers which generate heat and preserve heat are arranged; coating alcohol-based zircon powder coating on the contact surface of the upper and lower section steel water flows;
(3) core falling and mould assembling: after the upper and lower molds obtained in the step (2) are hardened and stripped, the coated sand shell core obtained in the step (1) falls into a lower box, a core falling gap is checked, whether the sand core is flush with the outline of the outer mold or not is checked, whether air outlet, a casting head and the like are smooth or not is checked, after the sand mold is cleaned up, a box closing pin is used for carrying out upper and lower box closing, box staggering is prevented, and a box clamp is tightened, so that a casting box is obtained;
(4) smelting and pouring: adopting a medium-frequency induction furnace for smelting and pouring, preheating the cavity of the casting box obtained in the step (3) before pouring, then injecting molten steel into the casting box, wherein the pouring temperature is 1570-1590 ℃, and cooling the molten steel to form a casting;
(5) opening the box and shakeout: opening the box after the casting obtained in the step (4) is cooled, wherein the cooling time is more than or equal to 6 hours, vibrating and shakeout the casting through a shakeout machine, and performing shot blasting treatment;
(6) cutting a casting head: performing dead head flame cutting on the casting obtained in the step (5) by adopting natural gas and other modes;
(7) normalizing heat treatment: carrying out normalizing heat treatment on the casting obtained in the step (6) by adopting a box type resistance furnace, wherein the heat preservation temperature is 910 +/-10 ℃;
(8) rough machining: machining the bottom plane and the machining hole of the casting obtained in the step (7);
(9) flaw detection, welding repair and polishing: performing magnetic powder inspection and ray inspection on the casting obtained in the step (8), and then adopting a welding electrode or CO2Welding and repairing the defects of the casting by gas shielded welding;
(10) quenching and tempering heat treatment: carrying out heat treatment on the casting obtained in the step (9) by using a box type resistance furnace, wherein the quenching temperature is 910 +/-10 ℃, and the tempering temperature is 650-690 ℃;
(11) magnetic powder inspection and appearance inspection: performing magnetic powder inspection on the casting obtained in the step (10), wherein the surface roughness of the casting requires Ra 50;
(12) finish machining: and (4) performing finish machining on the casting obtained in the step (11), wherein the finished surface is not allowed to have hole defects with the diameter larger than 1.5mm and the depth larger than 2mm, performing magnetic powder inspection on the finished casting, and putting the finished casting into a finished product warehouse after the finished casting is qualified.
The normal-temperature bending strength of the common cast steel precoated sand in the step (1) is 4.0-5.0 MPa, the appropriate reduction amount is less than or equal to 4.0%, the gas evolution amount is less than or equal to 25ml/g, and the Baume degree of the water-based zircon powder coating is 63 +/-2.
The standard of magnetic particle inspection in the step (9), the step (11) and the step (12) is TB/T9444-3 grade requirement, and the standard of radiographic inspection in the step (9) is ASTME 446. Wherein, the A class and the B class are 2 grades, the C class and the 3 grades, and D, E, F, G four types of defects are not allowed.
Compared with the prior art, the invention has the following advantages:
1. the precoated sand core adopts a standard part, the production efficiency can be improved by 20%, the product size precision is high, the machining allowance can be properly reduced by 4-8 mm, and the machining working hours of the casting can be reduced to a certain extent;
2. the casting is formed by a precoated sand shell mold and a shell core, the surface smoothness of the core is high, the deformability of the precoated sand core is excellent compared with that of the original sodium silicate sand core, casting defects such as casting air holes, sand washing, sand inclusion, sand adhesion, cracks and the like are effectively prevented, and the qualified rate of the casting can be improved by 30%; the casting has excellent appearance quality, can achieve higher surface smoothness, and has surface roughness of Ra 50;
3. the precoated sand has excellent collapsibility, greatly reduces the sand cleaning difficulty and workload of the casting, and improves the casting cleaning production efficiency.
Drawings
FIG. 1 is a flow chart of the present invention.
Detailed Description
The following examples are given for the detailed implementation and specific operation of the embodiments of the present invention, but the scope of the present invention is not limited to the following examples.
A method for producing a mounting seat steel casting based on a precoated sand shell mold process adopts upper and lower box molding, and is characterized in that: comprises the following steps of (a) carrying out,
(1) manufacturing a precoated sand mold core: manufacturing a precoated sand shell mold and a shell core by using a core shooter, wherein the thickness of the shell mold and the shell core is 12-16 mm, coating the precoated sand shell mold and the shell core with water-based zircon powder coating by using common cast steel, and placing the precoated sand shell mold and the shell core into a surface drying furnace for surface drying after dip coating;
(2) modeling: putting the coated sand shell mold obtained in the step (1) into a lower box for molding, wherein the first mold is four, and the sand box is filled with ester hardened water glass sand; the upper box is provided with a refractory pipe and risers, and each 6 risers which generate heat and preserve heat are arranged; coating alcohol-based zircon powder coating on the contact surface of the upper and lower section steel water flows;
(3) core falling and mould assembling: after the upper and lower molds obtained in the step (2) are hardened and stripped, dropping the coated sand shell core obtained in the step (1) into a lower box, and performing upper and lower box mould assembling by using a mould assembling pin after a sand mould is cleaned up to obtain a casting mould;
(4) smelting and pouring: adopting a medium-frequency induction furnace for smelting and pouring, preheating the cavity of the casting box obtained in the step (3) before pouring, then injecting molten steel into the casting box, wherein the pouring temperature is 1570-1590 ℃, and cooling the molten steel to form a casting;
(5) opening the box and shakeout: opening the box after the casting obtained in the step (4) is cooled, wherein the cooling time is more than or equal to 6 hours, vibrating and shakeout the casting through a shakeout machine, and performing shot blasting treatment;
(6) cutting a casting head: performing dead head flame cutting on the casting obtained in the step (5) by adopting natural gas and other modes;
(7) normalizing heat treatment: carrying out normalizing heat treatment on the casting obtained in the step (6) by adopting a box type resistance furnace, wherein the heat preservation temperature is 910 +/-10 ℃;
(8) rough machining: machining the bottom plane and the machining hole of the casting obtained in the step (7);
(9) flaw detection, welding repair and polishing: performing magnetic powder inspection and ray inspection on the casting obtained in the step (8), and then adopting a welding electrode or CO2Welding and repairing the defects of the casting by gas shielded welding;
(10) quenching and tempering heat treatment: carrying out heat treatment on the casting obtained in the step (9) by using a box type resistance furnace, wherein the quenching temperature is 910 +/-10 ℃, and the tempering temperature is 650-690 ℃;
(11) magnetic powder inspection and appearance inspection: carrying out magnetic powder inspection on the casting obtained in the step (10);
(12) finish machining: and (5) performing fine machining on the casting obtained in the step (11), performing magnetic powder inspection on the casting after the fine machining, and sending the casting into a finished product warehouse after the inspection is qualified.
The normal-temperature bending strength of the common cast steel precoated sand in the step (1) is 4.0-5.0 MPa, the appropriate reduction amount is less than or equal to 4.0%, the gas evolution is less than or equal to 25ml/g, and the Baume degree of the coating of the water-based zircon powder coating is 63 +/-2.
The standard of magnetic particle inspection in the step (9), the step (11) and the step (12) is TB/T9444-3 grade requirement, and the standard of radiographic inspection in the step (9) is ASTME 446. Wherein, the A class and the B class are 2 grades, the C class and the 3 grades, and D, E, F, G four types of defects are not allowed.
Claims (3)
1. A method for producing a mounting seat steel casting based on a precoated sand shell mold process adopts upper and lower box molding, and is characterized in that: comprises the following steps of (a) carrying out,
(1) manufacturing a precoated sand mold core: manufacturing a precoated sand shell mold and a shell core by using a core shooter, wherein the thickness of the shell mold and the shell core is 12-16 mm, coating the precoated sand shell mold and the shell core with water-based zircon powder coating by using common cast steel, and placing the precoated sand shell mold and the shell core into a surface drying furnace for surface drying after dip coating;
(2) modeling: putting the coated sand shell mold obtained in the step (1) into a lower box for molding, wherein the first mold is four, and the sand box is filled with ester hardened water glass sand; the upper box is provided with a refractory pipe and risers, and each 6 risers which generate heat and preserve heat are arranged; coating alcohol-based zircon powder coating on the contact surface of the upper and lower section steel water flows;
(3) core falling and mould assembling: after the upper and lower molds obtained in the step (2) are hardened and stripped, dropping the coated sand shell core obtained in the step (1) into a lower box, and performing upper and lower box mould assembling by using a mould assembling pin after the sand mould is cleaned up to obtain a casting mould;
(4) smelting and pouring: adopting a medium-frequency induction furnace for smelting and pouring, preheating the cavity of the casting box obtained in the step (3) before pouring, then injecting molten steel into the casting box, wherein the pouring temperature is 1570-1590 ℃, and cooling the molten steel to form a casting;
(5) opening the box and shakeout: opening the box after the casting obtained in the step (4) is cooled, wherein the cooling time is more than or equal to 6 hours, vibrating and shakeout the casting through a shakeout machine, and performing shot blasting treatment;
(6) cutting a casting head: performing dead head flame cutting on the casting obtained in the step (5) by adopting natural gas and other modes;
(7) normalizing heat treatment: carrying out normalizing heat treatment on the casting obtained in the step (6) by adopting a box type resistance furnace, wherein the heat preservation temperature is 910 +/-10 ℃;
(8) rough machining: machining the bottom plane and the machining hole of the casting obtained in the step (7);
(9) flaw detection, welding repair and polishing: performing magnetic powder inspection and ray inspection on the casting obtained in the step (8), and then adopting a welding electrode or CO2Welding and repairing the defects of the casting by gas shielded welding;
(10) quenching and tempering heat treatment: carrying out heat treatment on the casting obtained in the step (9) by using a box type resistance furnace, wherein the quenching temperature is 910 +/-10 ℃, and the tempering temperature is 650-690 ℃;
(11) magnetic powder inspection and appearance inspection: carrying out magnetic powder inspection on the casting obtained in the step (10);
(12) finish machining: and (5) performing fine machining on the casting obtained in the step (11), performing magnetic powder inspection on the casting after the fine machining, and sending the casting into a finished product warehouse after the inspection is qualified.
2. The method for producing the mount pad steel casting based on the precoated sand shell mold process according to claim 1, wherein: the normal-temperature bending strength of the common cast steel precoated sand in the step (1) is 4.0-5.0 MPa, the appropriate reduction amount is less than or equal to 4.0%, the gas evolution amount is less than or equal to 25ml/g, and the Baume degree of the water-based zircon powder coating is 63 +/-2.
3. The method for producing the mount pad steel casting based on the precoated sand shell mold process according to claim 1, wherein: the standard of magnetic particle inspection in the step (9), the step (11) and the step (12) is TB/T9444-3 grade requirement, and the standard of radiographic inspection in the step (9) is ASTME 446.
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| CN202011310356.7A CN112605338A (en) | 2020-11-20 | 2020-11-20 | Method for producing mounting seat steel casting based on precoated sand shell mold process |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN113680973A (en) * | 2021-09-01 | 2021-11-23 | 西峡县众德汽车部件有限公司 | Double-flow-passage volute top partition plate air hole and shrinkage porosity solving process |
| CN114769511A (en) * | 2022-04-13 | 2022-07-22 | 山东燕山精密机械有限公司 | Sand mould riser seat and application thereof |
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2020
- 2020-11-20 CN CN202011310356.7A patent/CN112605338A/en active Pending
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