CN113477885A - Composite molding process method of WCB valve steel casting - Google Patents
Composite molding process method of WCB valve steel casting Download PDFInfo
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- CN113477885A CN113477885A CN202110761831.0A CN202110761831A CN113477885A CN 113477885 A CN113477885 A CN 113477885A CN 202110761831 A CN202110761831 A CN 202110761831A CN 113477885 A CN113477885 A CN 113477885A
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- 238000005266 casting Methods 0.000 title claims abstract description 70
- 238000000034 method Methods 0.000 title claims abstract description 65
- 230000008569 process Effects 0.000 title claims abstract description 44
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 43
- 239000010959 steel Substances 0.000 title claims abstract description 43
- 239000002131 composite material Substances 0.000 title claims abstract description 37
- 238000000465 moulding Methods 0.000 title claims abstract description 36
- 239000004576 sand Substances 0.000 claims abstract description 140
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims abstract description 49
- 239000003110 molding sand Substances 0.000 claims abstract description 46
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims abstract description 37
- 239000005011 phenolic resin Substances 0.000 claims abstract description 37
- 229920001568 phenolic resin Polymers 0.000 claims abstract description 37
- 238000004519 manufacturing process Methods 0.000 claims abstract description 35
- 238000001514 detection method Methods 0.000 claims abstract description 32
- 235000019353 potassium silicate Nutrition 0.000 claims abstract description 26
- 230000008901 benefit Effects 0.000 claims abstract description 12
- 238000005516 engineering process Methods 0.000 claims abstract description 7
- 238000005457 optimization Methods 0.000 claims abstract description 7
- 230000007547 defect Effects 0.000 claims abstract description 6
- 238000004898 kneading Methods 0.000 claims abstract description 6
- 239000004115 Sodium Silicate Substances 0.000 claims description 23
- 229910052911 sodium silicate Inorganic materials 0.000 claims description 23
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 19
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 18
- 150000002148 esters Chemical class 0.000 claims description 16
- 244000035744 Hura crepitans Species 0.000 claims description 15
- 239000000463 material Substances 0.000 claims description 15
- 230000007246 mechanism Effects 0.000 claims description 13
- 238000005056 compaction Methods 0.000 claims description 10
- 238000012545 processing Methods 0.000 claims description 10
- 239000000126 substance Substances 0.000 claims description 10
- 238000009826 distribution Methods 0.000 claims description 9
- 229910052742 iron Inorganic materials 0.000 claims description 9
- 239000002245 particle Substances 0.000 claims description 9
- 238000012360 testing method Methods 0.000 claims description 9
- 238000003908 quality control method Methods 0.000 claims description 8
- 239000002184 metal Substances 0.000 claims description 7
- 229910052751 metal Inorganic materials 0.000 claims description 7
- 238000004140 cleaning Methods 0.000 claims description 6
- 238000005498 polishing Methods 0.000 claims description 6
- 239000000843 powder Substances 0.000 claims description 6
- 238000011112 process operation Methods 0.000 claims description 6
- 229920005989 resin Polymers 0.000 claims description 6
- 239000011347 resin Substances 0.000 claims description 6
- 238000005488 sandblasting Methods 0.000 claims description 6
- 238000013461 design Methods 0.000 claims description 4
- 238000003723 Smelting Methods 0.000 claims description 3
- 238000009825 accumulation Methods 0.000 claims description 3
- 239000002253 acid Substances 0.000 claims description 3
- 239000000956 alloy Substances 0.000 claims description 3
- 238000007664 blowing Methods 0.000 claims description 3
- 239000003795 chemical substances by application Substances 0.000 claims description 3
- 229910052681 coesite Inorganic materials 0.000 claims description 3
- 229910052906 cristobalite Inorganic materials 0.000 claims description 3
- 238000007689 inspection Methods 0.000 claims description 3
- 229910001338 liquidmetal Inorganic materials 0.000 claims description 3
- 238000003754 machining Methods 0.000 claims description 3
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 230000001172 regenerating effect Effects 0.000 claims description 3
- 239000000523 sample Substances 0.000 claims description 3
- 239000000377 silicon dioxide Substances 0.000 claims description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052682 stishovite Inorganic materials 0.000 claims description 3
- 229910052905 tridymite Inorganic materials 0.000 claims description 3
- 238000005303 weighing Methods 0.000 claims description 3
- 230000007613 environmental effect Effects 0.000 abstract 1
- 229910001208 Crucible steel Inorganic materials 0.000 description 5
- 239000000047 product Substances 0.000 description 4
- 239000007789 gas Substances 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 238000011897 real-time detection Methods 0.000 description 1
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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
- B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
- B22C1/16—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents
- B22C1/20—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents
- B22C1/22—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins
- B22C1/2233—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds characterised by the use of binding agents; Mixtures of binding agents of organic agents of resins or rosins obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- B22C1/2246—Condensation polymers of aldehydes and ketones
- B22C1/2253—Condensation polymers of aldehydes and ketones with phenols
-
- 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
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/12—Treating moulds or cores, e.g. drying, hardening
- B22C9/123—Gas-hardening
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
- G01D21/02—Measuring two or more variables by means not covered by a single other subclass
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Mold Materials And Core Materials (AREA)
Abstract
The invention discloses a composite molding process method of a WCB valve steel casting, which comprises the steps of designing a molding sand quality online detection and control optimization system to enable an online detection technology to be established on the basis of system component balance, ensuring the stability of the system, designing an alkaline phenolic resin surface sand and ester-hardened water glass back sand composite molding process to achieve the advantages of kneading the molding sand of the molding sand and the molding sand of the molding sand, abandoning the defects of the molding sand, having low comprehensive cost, environmental protection and better economic benefit, producing a WCB valve steel casting mold and manufacturing the WCB valve steel casting mold, and solving the molding problems of high demolding labor intensity, low production efficiency, unstable product quality and the like by designing and developing the WCB valve steel casting mold. According to the invention, the production of the valve steel casting is completed by designing the composite molding process of the WCB valve steel casting, and the production quality is effectively improved.
Description
Technical Field
The invention relates to the technical field of metal processing technology, in particular to a composite modeling process method of a WCB valve steel casting.
Background
Cast steel valves are one of many valve types and are made of cast steel (carbon steel). The applicable temperature of the cast steel valve is less than or equal to 425 ℃, and the applicable medium is as follows: water, petroleum, natural gas and the like, and the cast steel materials (WCA, WCB and WCC) are suitable for pipelines with nominal pressure PN less than or equal to 40MPa and the working temperature is between-29 and 425 ℃.
The final product produced by the traditional cast steel valve production process is easy to generate high temperature resistance and high pressure resistance, so certain quality problems are easy to occur in the subsequent use of the product, and the casting is easy to be doped with harmful impurities, so that the water quality is easy to be polluted. Therefore, the method is improved, and a composite molding process method of the WCB valve steel casting is provided.
Disclosure of Invention
In order to solve the technical problems, the invention provides the following technical scheme:
the invention relates to a composite modeling process method of a WCB valve steel casting, which comprises the following steps:
s1: design molding sand quality on-line detection and control optimization system
A set of complete intelligent molding sand quality control system is designed, the system utilizes an online detection device to control the compaction rate of molding sand, and combines with an online material replenishing system, so that the online detection technology is established on the basis of system component balance, and the stability of the system is ensured;
s2: composite molding process for designing alkaline phenolic resin surface sand and ester-hardened water glass back sand
According to the difference of the reaction mechanisms of the chemical curing of the alkaline phenolic resin sand and the ester-hardened sodium silicate sand, the formula of the alkaline phenolic resin sand and the process of the ester-hardened sodium silicate sand are adjusted, so that the alkaline phenolic resin sand and the ester-hardened sodium silicate sand are firmly bonded, the advantages of kneading the molding sand of the alkaline phenolic resin sand and the ester-hardened sodium silicate sand are achieved, the defects of the molding sand of the alkaline phenolic resin sand and the ester-hardened sodium silicate sand are eliminated, the comprehensive cost is low, the environment is protected, and the economic benefit is better;
s3: casting die for producing WCB material valve steel castings and production and manufacturing
By designing and developing the casting mould of the WCB material valve steel casting, the problems of high demoulding labor intensity, low production efficiency, unstable product quality and other modeling problems are solved.
As a preferred technical solution of the present invention, the on-line sand quality detecting system in step S1 includes:
the central PLC control unit is used for acquiring and receiving the detection result and controlling other units;
the online sand moisture detection unit is used for detecting the moisture and the temperature of the sand before mixing;
the online compaction rate tester is used for extracting sand samples from the sand mixer to detect the compaction rate;
and the water adding system is used for adding water into the sand mixer.
As a preferable embodiment of the present invention, the quality test criteria of the molding sand are as follows
Raw yarn: water content is less than or equal to 0.3%, mud content: the diameter is less than or equal to 0.022mm, and the particle size distribution is as follows: 30/50 mesh or more than 95 percent and SiO2The content is more than or equal to 90 percent, the acid consumption value is less than 5ml/50g, and the strength of the test block is more than or equal to 0.4 MPa;
surface yarn: the water content is less than or equal to 0.1 percent, the particle size distribution is 30/50 meshes or more than 95 percent, the micro powder content is less than 0.3 percent, the ignition loss is less than 0.5 percent, the sand temperature is 20-30 ℃, and the test block strength is more than or equal to 0.4;
back sanding: water content less than or equal to 0.1%, particle size distribution: the 30/50 meshes is more than or equal to 95 percent, the micro powder content is less than 0.3 percent, the ignition loss is less than 1.5 percent, and the sand temperature is 20-30 ℃.
As a preferred technical scheme of the invention, the molding sand quality control optimization system is electrically connected with a multi-azimuth detection mechanism, and the multi-azimuth detection mechanism comprises a pressure sensor for weighing, a temperature detection probe, a flow control valve and a water pressure sensor.
As a preferred technical solution of the present invention, the alkaline phenolic resin surface sand and ester-hardened water glass back sand composite molding process in step S2 includes:
s2.1: adjusting the formula proportion of the alkaline phenolic resin facing sand, and slowing down the hardening speed of the resin sand;
s2.2: designing an ester hardening water glass back sanding process;
s2.3: carrying out composite modeling process operation and production.
As a preferred embodiment of the present invention,
in the step S2.1, the hardening time of the alkaline phenolic resin surface sand is close to that of the ester hardening water glass back sand, and the proportion is
100 parts of raw sand: resin (1-2): a curing agent (0.5 to 1.2);
in the step S2.2, the ester hardening water glass is prepared from water glass with Baume degree of 51 and modulus of 1.85 according to the proportion
Regenerating used sand by water glass: water glass: ester 100: (2.5-3.3): (0.2-0.35).
As a preferred technical scheme of the present invention, the specific steps of the composite modeling process operation and production in step S2.3 are as follows:
s2.3.1: preparing a production mold, and then placing and fixing the mold;
s2.3.2: directly covering the mould by using facing sand, and tightly piling the covered part in the covering process;
s2.3.3: when the surface sand begins to cover the model, releasing the back sand, releasing the sand from the position covered with the surface sand, placing the back sand according to an alkaline surface sand releasing line until the sand box is filled, and inserting the sand lifting hook into a surface sand layer when the sand lifting hook is placed in the sand releasing process;
s2.3.4: after the sand box is placed stably and scraped flatly, exhaust holes are formed in the sand box at intervals of 100-400 mm through steel needles, CO2 gas is blown in along the exhaust holes after the molding sand is placed and hardened for 1 hour, the molding sand is further hardened, the blowing time is 2-4 seconds, and the box is turned over and the mold is taken after the molding sand is turned over.
As a preferred embodiment of the present invention,
the production steps of the valve steel casting mold in the step S3 are as follows:
a molding stage: manufacturing a mold and a core box according to a valve drawing for realizing production;
a modeling stage: molding by using a molding sand accumulation cavity, then making cores, then putting the mud cores into the cavity, and then combining an upper sand box and a lower sand box for film matching;
a smelting stage: chemical components are prepared according to the required metal components, and a proper melting furnace is selected to melt alloy materials to form qualified liquid metal (including qualified components and qualified temperature);
and (3) pouring stage: pouring molten iron melted in the electric furnace into the manufactured mold by using a ladle, wherein the pouring speed of the molten iron needs to be noticed, so that the molten iron is filled in the whole cavity;
a cleaning stage: after pouring and after the molten metal is solidified, taking a hammer to remove a pouring gate and shaking off sand of the casting, and then carrying out sand blasting by using a sand blasting machine;
processing the casting: for some castings with special requirements or some castings which cannot meet the requirements, simple processing is carried out, and a grinding wheel or a polishing machine is generally used for processing and polishing to remove burrs so that the castings are smoother;
and (3) inspecting the casting: inspection of castings-typically during the cleaning or machining stage, unqualified castings are cleaned.
The invention has the beneficial effects that:
1. according to the WCB material valve steel casting composite modeling process method, a complete intelligent molding sand quality control system is designed, an online detection device is used for controlling the compaction rate of molding sand, and an online material replenishing system is combined, so that an online detection technology is established on the basis of system component balance, and the stability of the system is guaranteed;
2. according to the composite molding process method of the WCB material valve steel casting, the alkaline phenolic resin sand formula and the ester hardening sodium silicate sand technology are adjusted according to different chemical curing reaction mechanisms of the alkaline phenolic resin sand and the ester hardening sodium silicate sand, so that the alkaline phenolic resin surface sand and the ester hardening sodium silicate sand are firmly bonded, the advantages of kneading the two molding sands are achieved, the defects are eliminated, the comprehensive cost is low, the environment is protected, and the economic benefit is better;
3. according to the composite molding process method of the WCB valve steel casting, the molding problems of high demolding labor intensity, low production efficiency, unstable product quality and the like are solved by designing and developing a casting mold of the WCB valve steel casting.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention.
In the drawings:
FIG. 1 is a flow chart of a composite modeling process of a WCB valve steel casting of the present invention;
FIG. 2 is a system flow chart of an alkaline phenolic resin surface sand and ester-hardened water glass back sand composite molding process of the WCB valve steel casting composite molding process method of the present invention;
FIG. 3 is a system flow chart of the specific steps of the composite molding process operation production of the composite molding process method of the WCB material valve steel casting of the present invention;
FIG. 4 is a system flow chart of the steps of the valve steel casting mold production process of the WCB valve steel casting composite molding process of the present invention.
Detailed Description
The preferred embodiments of the present invention will be described in conjunction with the accompanying drawings, and it will be understood that they are described herein for the purpose of illustration and explanation and not limitation.
Example (b): as shown in fig. 1 to 4, the composite molding process method of the WCB valve steel casting of the present invention comprises the following steps:
s1: design molding sand quality on-line detection and control optimization system
A set of complete intelligent molding sand quality control system is designed, the system utilizes an online detection device to control the compaction rate of molding sand, and combines with an online material replenishing system, so that the online detection technology is established on the basis of system component balance, and the stability of the system is ensured;
s2: composite molding process for designing alkaline phenolic resin surface sand and ester-hardened water glass back sand
According to the difference of the reaction mechanisms of the chemical curing of the alkaline phenolic resin sand and the ester-hardened sodium silicate sand, the formula of the alkaline phenolic resin sand and the process of the ester-hardened sodium silicate sand are adjusted, so that the alkaline phenolic resin sand and the ester-hardened sodium silicate sand are firmly bonded, the advantages of kneading the molding sand of the alkaline phenolic resin sand and the ester-hardened sodium silicate sand are achieved, the defects of the molding sand of the alkaline phenolic resin sand and the ester-hardened sodium silicate sand are eliminated, the comprehensive cost is low, the environment is protected, and the economic benefit is better;
s3: casting die for producing WCB material valve steel castings and production and manufacturing
By designing and developing the casting mould of the WCB material valve steel casting, the problems of high demoulding labor intensity, low production efficiency, unstable product quality and other modeling problems are solved.
Wherein, the online quality detection system for medium sand in step S1 includes:
the central PLC control unit is used for acquiring and receiving the detection result and controlling other units;
the online sand moisture detection unit is used for detecting the moisture and the temperature of the sand before mixing;
the online compaction rate tester is used for extracting sand samples from the sand mixer to detect the compaction rate;
and the water adding system is used for adding water into the sand mixer.
Through the quality on-line measuring system who designs, be convenient for control the quality of the molding sand of casting usefulness before the steel casting to reduce the inside bubble of steel casting after the production, and effectively avoid the inside humidity of steel casting unqualified.
Wherein the quality test standard of the molding sand is as follows
Raw yarn: water content is less than or equal to 0.3%, mud content: the diameter is less than or equal to 0.022mm, and the particle size distribution is as follows: 30/50 mesh or more than 95 percent and SiO2The content is more than or equal to 90 percent, the acid consumption value is less than 5ml/50g, and the strength of the test block is more than or equal to 0.4 MPa;
surface yarn: the water content is less than or equal to 0.1 percent, the particle size distribution is 30/50 meshes or more than 95 percent, the micro powder content is less than 0.3 percent, the ignition loss is less than 0.5 percent, the sand temperature is 20-30 ℃, and the test block strength is more than or equal to 0.4;
back sanding: water content less than or equal to 0.1%, particle size distribution: the 30/50 meshes is more than or equal to 95 percent, the micro powder content is less than 0.3 percent, the ignition loss is less than 1.5 percent, and the sand temperature is 20-30 ℃.
Through designing the molding sand detection standard, the system of being convenient for carries out automatic matching and screening, has improved the efficiency to molding sand quality control.
Wherein, molding sand quality control optimization system electric connection has diversified detection mechanism, and diversified detection mechanism is including weighing with pressure sensor, temperature detect probe, flow control valve, pressure sensor.
Through the diversified detection mechanism that is equipped with, diversified detection mechanism can select the molding sand and follow-up making a mould carries out real-time detection, ensures the service quality of molding sand.
Wherein, the alkaline phenolic resin surface sand and ester hardening water glass back sand composite molding process in the step S2 comprises the following steps:
s2.1: adjusting the formula proportion of the alkaline phenolic resin facing sand, and slowing down the hardening speed of the resin sand;
s2.2: designing an ester hardening water glass back sanding process;
s2.3: carrying out composite modeling process operation and production.
The alkaline phenolic resin sand and the ester-hardened sodium silicate sand have different chemical curing reaction mechanisms, and the alkaline phenolic resin sand formula and the ester-hardened sodium silicate back sand process are adjusted, so that the alkaline phenolic resin sand and the ester-hardened sodium silicate back sand are firmly bonded, the advantages of kneading the alkaline phenolic resin sand and the ester-hardened sodium silicate back sand are achieved, the defects of the alkaline phenolic resin sand and the ester-hardened sodium silicate back sand are eliminated, the comprehensive cost is low, the environment is protected, and the economic benefit is better.
Wherein the content of the first and second substances,
in the step S2.1, the hardening time of the alkaline phenolic resin surface sand is close to that of the ester hardening water glass back sand, and the proportion is
100 parts of raw sand: resin (1-2): a curing agent (0.5 to 1.2);
in step S2.2, the ester hardening water glass is prepared from water glass with Baume degree of 51 and modulus of 1.85
Regenerating used sand by water glass: water glass: ester 100: (2.5-3.3): (0.2-0.35).
The concrete steps of the operation and production of the composite modeling process in the step S2.3 are as follows:
s2.3.1: preparing a production mold, and then placing and fixing the mold;
s2.3.2: directly covering the mould by using facing sand, and tightly piling the covered part in the covering process;
s2.3.3: when the surface sand begins to cover the model, releasing the back sand, releasing the sand from the position covered with the surface sand, placing the back sand according to an alkaline surface sand releasing line until the sand box is filled, and inserting the sand lifting hook into a surface sand layer when the sand lifting hook is placed in the sand releasing process;
s2.3.4: after the sand box is placed stably and scraped flatly, exhaust holes are formed in the sand box at intervals of 100-400 mm through steel needles, CO2 gas is blown in along the exhaust holes after the molding sand is placed and hardened for 1 hour, the molding sand is further hardened, the blowing time is 2-4 seconds, and the box is turned over and the mold is taken after the molding sand is turned over.
Wherein the content of the first and second substances,
the production steps of the valve steel casting mold in the step S3 are as follows:
a molding stage: manufacturing a mold and a core box according to a valve drawing for realizing production;
a modeling stage: molding by using a molding sand accumulation cavity, then making cores, then putting the mud cores into the cavity, and then combining an upper sand box and a lower sand box for film matching;
a smelting stage: chemical components are prepared according to the required metal components, and a proper melting furnace is selected to melt alloy materials to form qualified liquid metal (including qualified components and qualified temperature);
and (3) pouring stage: pouring molten iron melted in the electric furnace into the manufactured mold by using a ladle, wherein the pouring speed of the molten iron needs to be noticed, so that the molten iron is filled in the whole cavity;
a cleaning stage: after pouring and after the molten metal is solidified, taking a hammer to remove a pouring gate and shaking off sand of the casting, and then carrying out sand blasting by using a sand blasting machine;
processing the casting: for some castings with special requirements or some castings which cannot meet the requirements, simple processing is carried out, and a grinding wheel or a polishing machine is generally used for processing and polishing to remove burrs so that the castings are smoother;
and (3) inspecting the casting: inspection of castings-typically during the cleaning or machining stage, unqualified castings are cleaned.
Although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that changes may be made in the embodiments and/or equivalents thereof without departing from the spirit and scope of the invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (8)
1. A composite modeling process method of a WCB valve steel casting is characterized by comprising the following steps:
s1: design molding sand quality on-line detection and control optimization system
A set of complete intelligent molding sand quality control system is designed, the system utilizes an online detection device to control the compaction rate of molding sand, and combines with an online material replenishing system, so that the online detection technology is established on the basis of system component balance, and the stability of the system is ensured;
s2: composite molding process for designing alkaline phenolic resin surface sand and ester-hardened water glass back sand
According to the difference of the reaction mechanisms of the chemical curing of the alkaline phenolic resin sand and the ester-hardened sodium silicate sand, the formula of the alkaline phenolic resin sand and the process of the ester-hardened sodium silicate sand are adjusted, so that the alkaline phenolic resin sand and the ester-hardened sodium silicate sand are firmly bonded, the advantages of kneading the molding sand of the alkaline phenolic resin sand and the ester-hardened sodium silicate sand are achieved, the defects of the molding sand of the alkaline phenolic resin sand and the ester-hardened sodium silicate sand are eliminated, the comprehensive cost is low, the environment is protected, and the economic benefit is better;
s3: casting die for producing WCB material valve steel castings and production and manufacturing
By designing and developing the casting mould of the WCB material valve steel casting, the problems of high demoulding labor intensity, low production efficiency, unstable product quality and other modeling problems are solved.
2. The composite molding process method of the WCB valve steel casting as claimed in claim 1, wherein the on-line sand quality detection system in step S1 includes:
the central PLC control unit is used for acquiring and receiving the detection result and controlling other units;
the online sand moisture detection unit is used for detecting the moisture and the temperature of the sand before mixing;
the online compaction rate tester is used for extracting sand samples from the sand mixer to detect the compaction rate;
and the water adding system is used for adding water into the sand mixer.
3. The method of claim 2, wherein the molding sand has a quality test standard as follows
Raw yarn: water content is less than or equal to 0.3%, mud content: the diameter is less than or equal to 0.022mm, and the particle size distribution is as follows: 30/50 mesh or more than 95 percent and SiO2The content is more than or equal to 90 percent, the acid consumption value is less than 5ml/50g, and the strength of the test block is more than or equal to 0.4 MPa;
surface yarn: the water content is less than or equal to 0.1 percent, the particle size distribution is 30/50 meshes or more than 95 percent, the micro powder content is less than 0.3 percent, the ignition loss is less than 0.5 percent, the sand temperature is 20-30 ℃, and the test block strength is more than or equal to 0.4;
back sanding: water content less than or equal to 0.1%, particle size distribution: the 30/50 meshes is more than or equal to 95 percent, the micro powder content is less than 0.3 percent, the ignition loss is less than 1.5 percent, and the sand temperature is 20-30 ℃.
4. The composite molding process method of the WCB material valve steel casting of claim 2, wherein the molding sand quality control optimization system is electrically connected with a multi-azimuth detection mechanism, and the multi-azimuth detection mechanism comprises a pressure sensor for weighing, a temperature detection probe, a flow control valve and a water pressure sensor.
5. The composite molding process method of a WCB valve steel casting according to claim 1, wherein the composite molding process of the alkaline phenolic resin facing sand and the ester-hardened water glass back sand in step S2 includes:
s2.1: adjusting the formula proportion of the alkaline phenolic resin facing sand, and slowing down the hardening speed of the resin sand;
s2.2: designing an ester hardening water glass back sanding process;
s2.3: carrying out composite modeling process operation and production.
6. The composite molding process method of WCB valve steel castings according to claim 5, wherein,
in the step S2.1, the hardening time of the alkaline phenolic resin surface sand is close to that of the ester hardening water glass back sand, and the proportion is
100 parts of raw sand: resin (1-2): a curing agent (0.5 to 1.2);
in the step S2.2, the ester hardening water glass is prepared from water glass with Baume degree of 51 and modulus of 1.85 according to the proportion
Regenerating used sand by water glass: water glass: ester 100: (2.5-3.3): (0.2-0.35).
7. The composite molding process method for the WCB valve steel casting according to claim 5, wherein the composite molding process operation in the step S2.3 comprises the following steps:
s2.3.1: preparing a production mold, and then placing and fixing the mold;
s2.3.2: directly covering the mould by using facing sand, and tightly piling the covered part in the covering process;
s2.3.3: when the surface sand begins to cover the model, releasing the back sand, releasing the sand from the position covered with the surface sand, placing the back sand according to an alkaline surface sand releasing line until the sand box is filled, and inserting the sand lifting hook into a surface sand layer when the sand lifting hook is placed in the sand releasing process;
s2.3.4: after the sand box is placed stably and scraped flatly, exhaust holes are formed in the sand box at intervals of 100-400 mm through steel needles, CO2 gas is blown in along the exhaust holes after the molding sand is placed and hardened for 1 hour, the molding sand is further hardened, the blowing time is 2-4 seconds, and the box is turned over and the mold is taken after the molding sand is turned over.
8. The composite molding process method of WCB valve steel castings according to claim 1, wherein,
the production steps of the valve steel casting mold in the step S3 are as follows:
a molding stage: manufacturing a mold and a core box according to a valve drawing for realizing production;
a modeling stage: molding by using a molding sand accumulation cavity, then making cores, then putting the mud cores into the cavity, and then combining an upper sand box and a lower sand box for film matching;
a smelting stage: chemical components are prepared according to the required metal components, and a proper melting furnace is selected to melt alloy materials to form qualified liquid metal (including qualified components and qualified temperature);
and (3) pouring stage: pouring molten iron melted in the electric furnace into the manufactured mold by using a ladle, wherein the pouring speed of the molten iron needs to be noticed, so that the molten iron is filled in the whole cavity;
a cleaning stage: after pouring and after the molten metal is solidified, taking a hammer to remove a pouring gate and shaking off sand of the casting, and then carrying out sand blasting by using a sand blasting machine;
processing the casting: for some castings with special requirements or some castings which cannot meet the requirements, simple processing is carried out, and a grinding wheel or a polishing machine is generally used for processing and polishing to remove burrs so that the castings are smoother;
and (3) inspecting the casting: inspection of castings-typically during the cleaning or machining stage, unqualified castings are cleaned.
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