CN1552542A - Design method and system for no air gap stable filling casting - Google Patents
Design method and system for no air gap stable filling casting Download PDFInfo
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- CN1552542A CN1552542A CNA2003101052170A CN200310105217A CN1552542A CN 1552542 A CN1552542 A CN 1552542A CN A2003101052170 A CNA2003101052170 A CN A2003101052170A CN 200310105217 A CN200310105217 A CN 200310105217A CN 1552542 A CN1552542 A CN 1552542A
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- 238000000034 method Methods 0.000 title claims abstract description 17
- 238000005266 casting Methods 0.000 title abstract description 13
- 229910052751 metal Inorganic materials 0.000 claims abstract description 35
- 239000002184 metal Substances 0.000 claims abstract description 35
- 230000007704 transition Effects 0.000 claims description 12
- 238000005429 filling process Methods 0.000 claims description 8
- 208000037656 Respiratory Sounds Diseases 0.000 claims description 6
- 230000007547 defect Effects 0.000 claims description 6
- 239000002893 slag Substances 0.000 claims description 5
- 101100327917 Caenorhabditis elegans chup-1 gene Proteins 0.000 claims description 2
- 230000002950 deficient Effects 0.000 description 7
- 229910001338 liquidmetal Inorganic materials 0.000 description 6
- 229910001208 Crucible steel Inorganic materials 0.000 description 5
- 230000015572 biosynthetic process Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
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- 229910000831 Steel Inorganic materials 0.000 description 2
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- 239000000956 alloy Substances 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000005495 investment casting Methods 0.000 description 2
- 238000010120 permanent mold casting Methods 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 238000007528 sand casting Methods 0.000 description 2
- 230000006641 stabilisation Effects 0.000 description 2
- 238000011105 stabilization Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 241001672694 Citrus reticulata Species 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000009749 continuous casting Methods 0.000 description 1
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- 230000026676 system process Effects 0.000 description 1
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Abstract
A method for designing the non-air-gap smooth-filling casting features controlling the filling smoothness, lowering the filling speed, preventing air and oxidized film from coming in molten metal, reducing the size of pouring channel, and increasing the technological output rate. Its casting system has a pouring cup, a plug rod system connected with said pouring cup and opened when filled molten metal in the pouring cup reaches its 1/2-1/3 height, and the arc corner between vertical and horizontal pouring channels. Its pouring speed is 0.5-1.0 m/s.
Description
Technical field
The present invention relates to the Design of Runner System of casting process, specifically a kind of no air gap steadily fills type Pouring System Design Method and used running gate system, and it can generally be applicable to the Design of Runner System of sand casting, permanent mold casting and the hot investment casting of non-ferrous metal, ferrous metal, high temperature alloy etc.
Background technology
Traditional Design of Runner System normally closed (pressured) and open (unpressured) two kinds of methods.The basal area of the sprue of positive-pressure gating system, cross gate, ingate progressively diminishes, and the molten metal flow velocity is too fast, and turbulent flow is serious, easy scour cast, cause volume gas and inclusion defect (X ray is observed and shown, filling velocity causes turbulent flow and volume gas defective easily greater than 0.5m/s the time).The basal area of the sprue of unchoked running system, cross gate, ingate progressively enlarges, when causing liquid metal filling, in running channel, there is very air gaps, gas and molten metal interact, form oxide-film, gas and oxide-film are involved in the molten metal, form crackle and loose source, foundry goods are cracked and rarefaction defect.
Summary of the invention
Design method of the present invention is: the stationarity of control cavity filling process, reduce filling velocity; Make molten metal in running gate system, constantly be in full state, prevent that gas and oxide-film are involved in the molten metal, cause crackle and rarefaction defect; According to the principle that flow equates, reduce the design size of running channel in the running gate system, improve product yield.
Wherein: described cup links to each other with a stopper rod system, when the stopper rod system is opened in the molten metal filling to for cup 1/2～2/3 height the time; Arc transition is adopted in described sprue and cross gate corner; Described filling velocity can be controlled between 0.5m/s～1.0m/s; Can also be by in described cross gate, adding screen pack or rotating slag trap and control poring rate.According to the different running gate system size of actual conditions design of foundry goods, but cardinal principle is to prevent to roll up gas and produce a large amount of oxide-films in molten metal.
Invent the composition of used running gate system: mainly comprise cup, and sprue that is attached thereto and cross gate; Described cup with feed opening is an eccentric structure, it is the relatively side at cup center that cast gate is located at cup, the internal orifice of its feed opening is provided with the projective table type port, and cup links to each other with a stopper rod system, the free end of stopper rod dynamically contacts with internal orifice, guarantees to fill type after liquid level reach a certain height in the cup; Used sprue has been considered the influence of factors such as initial velocity and friction according to the design of flow equal principle, adopts up big and down small streamlined structure; Sprue and cross gate corner cancellation well are used arc transition instead, and its radius of corner is at least a times of cross gate diameter; Its cross gate (is provided with screen pack or at the end of cross gate the speed that a rotation slag trap reduces ingate is set.) design mainly reduce flow velocity, guarantee simultaneously to be full of; In order further to reduce filling velocity, guarantee that die cavity becomes a mandarin steadily.
The invention belongs to no air gap and steadily fill type running gate system (natural pressured), it is according to fluid mechanics principle, in conjunction with inventor's research work for many years, X ray Real Time Observation technology particularly, control liquid metal filling speed, and while control liquid metal filling mode (being flow regime) on the basis of improving structure, make molten metal in running gate system, be in full state, no air gap, no disturbance, do not roll up gas and do not form oxide-film, defectives such as foundry goods is difficult for cracking, loosens and is mingled with, the performance and the service life of greatly improving foundry goods.
The present invention has following beneficial effect:
1. because the present invention has reduced filling velocity, be full of a certain amount of metal in the cup earlier, avoided the generation of splash phenomena, the stationarity of control cavity filling process, make molten metal in running gate system, be in full state constantly, no gas and oxide-film are involved in the molten metal, are difficult for causing crackle and defective such as loose.And adopt round-corner transition to replace incorrect ways such as traditional right angle transition or placement well, and reduce the design size of running gate system, improved product yield greatly.
2. the present invention controls liquid metal filling mode (being flow regime) on the basis of improving structure, not only make molten metal in running gate system, be in full state, no air gap, no disturbance, do not roll up gas and do not form oxide-film, defectives such as foundry goods is difficult for cracking, loosens and is mingled with, the performance and the service life of greatly having improved foundry goods simultaneously.
3. Pouring System Design Method of the present invention generally is applicable to technologies such as the sand casting, permanent mold casting, hot investment casting of various alloys, and along with the raising to casting quality and service life, this no air gap steadily fills the type running gate system will become new design principle.
Description of drawings
The Design of Runner System schematic diagram that Fig. 1 is traditional.
Fig. 2 Design of Runner System schematic diagram of the present invention.
Traditional Design of Runner System of Fig. 3 cast steel roll.
The running gate system structural representation that Fig. 4 the present invention is new; Wherein: 41 is base, and 42 are following roll neck nowel swage, and 43 are following roll neck top box swage, 44 is body of roll swage, and 45 is last roll neck case swage, and 46 is rising head case swage, 47 is tundish, 48 is the current stabilization platform in the tundish, and 49 is the down gate top box, and 32 is sprue, 411 is the down gate case, 412 is the down gate nowel, and 33 is the transition arc of sprue and cross gate junction, and 34 is cross gate.
Fig. 5 adopts the backing roll figure of the new Design of Runner System process casting of the present invention.
Fig. 6 adopts the surface appearance figure after the cast steel support roller heat treatment of the new Design of Runner System of the present invention.
The specific embodiment
Below in conjunction with drawings and Examples in detail the present invention is described in detail.
Embodiment 1
With large-scale integral casting cast steel support roller is example, material 40Cr4, molten steel weight 50t, filling time 7～8min, 1550 ℃ of pouring temperatures.
As shown in Figure 4, casting and pouring method and system structure of the present invention is as follows: 1) according to the principle design cup that steadily fills type.At the port of export design projective table type current stabilization platform 48 of cup, molten metal does not produce splash phenomena in cavity filling process.The internal orifice of cup feed opening links to each other with a stopper rod system, opens the stopper rod system when the molten metal filling during to cup 2/3 height, helps getting rid of in cavity filling process oxide inclusion, and it is steady also to help liquid metal filling.2) adopt up big and down small streamlined sprue structure, the specific serial connection by the multistage sprue forms (present embodiment is 4 sections), according to the principle that flow equates, calculates the size of each joint of sprue, fills the reasonability that pattern intends checking design by computer again; Present embodiment inlet diameter 123mm, outlet diameter 63mm.3) adopt arc transition 33 in described cross gate 34 and sprue 32 junctions, radius of corner is 120mm.Such design has guaranteed that molten metal constantly is in full state in running gate system, in the cavity filling process steadily, being involved in of no gas and oxide-film.
As shown in Figure 2, casting of molten metal of the present invention is in full state all the time in cavity filling process, does not give the gas leaving space, therefore can not form defectives such as volume gas and oxide-film, can not crack and rarefaction defect in foundry goods.Wherein: 1 is molten metal, and 2 is sand mold.
The course of work of the present invention and result:
Because the present invention has partly used stopper rod system (stopper) at cup, when cast, molten metal at first is filled to cup more than 2/3 height, opens the stopper rod system then, and molten metal flows into sprue 32.Such design assurance field trash etc. floats to the top of cup, simultaneously in the incipient stage of filling type, can guarantee that molten metal is full of casting mold.Sprue 32 is up big and down small, guarantees constantly to be in full state, and sprue 32 adopts arc transition with cross gate 34.Molten metal steadily flows in the die cavity.
The weight of the cast steel liquid metal of present embodiment is 50t, and the roll maximum gauge is 1435mm, and the height of running gate system is the 6.5m height.Filling time is 7.5min, observes casting process, finds the molten metal cleaning, rises steadily.Cast back shake out after 40h hour, surface quality of continuous castings good (referring to Fig. 5).Do not find defectives (referring to Fig. 6) such as crackle in the high-temperature annealing process.
In addition, at medium and small foundry goods, filling velocity of the present invention can be controlled between 0.5m/s～1.0m/s; At the heavier situation of aluminium alloy castings oxidation, the present invention can be by adding screen pack or rotating slag trap and control poring rate in described cross gate.
Comparative example
As shown in Figure 1, molten metal is in half full state in the prior art in cavity filling process, reserves very large space to gas, and molten metal and gas reaction form oxide-film and be involved in formation crackle and rarefaction defect in the foundry goods.Wherein: 1 is molten metal, and 2 is sand mold, and 3 is gas.
Shown in Figure 3 is the Design of Runner System of very typical conventional cast cast steel roll.Cup 31 adopts conical design, and sprue 32 adopts steel brick pipe, and diameter dimension is identical up and down.General about 10 tons steel-casting sprue 32 sizes are about 100～120mm.Adopt the right angle transition in sprue 32 and cross gate 34 junctions, place well usually.The size of cross gate 34 does not change.She Ji shortcoming is like this: 1) cup can not be full of, and metal flow is more and more thinner in sprue, causes gas that very big space is arranged.Molten metal and gas reaction fierceness, the oxide-film of formation is involved in the molten metal.Owing to be the right angle transition, cause turbulent flow and volume gas phenomenon in the junction easily.The cross gate size is very big, can not be in full state in the incipient stage of filling type, causes volume gas and oxide-film equally, and these all are fearful formation of crack, causes roll hot tearing, defective such as loose easily, in use ruptures easily or peels off.
Claims (8)
1. a no air gap steadily fills the type Pouring System Design Method, it is characterized in that: the stationarity of control cavity filling process, reduce filling velocity; Make molten metal in running gate system, constantly be in full state, prevent that gas and oxide-film are involved in the molten metal, cause crackle and rarefaction defect; According to the principle that flow equates, reduce the design size of running channel in the running gate system, improve product yield.
2. steadily fill the type Pouring System Design Method according to the described no air gap of claim 1, it is characterized in that: described cup links to each other with a stopper rod system, when the stopper rod system is opened in the molten metal filling to for cup 1/2～2/3 height the time.
3. steadily fill the type Pouring System Design Method according to the described no air gap of claim 1, it is characterized in that: arc transition is adopted in described sprue and cross gate corner.
4. steadily fill the type Pouring System Design Method according to the described no air gap of claim 1, it is characterized in that: described filling velocity can be controlled between 0.5m/s～1.0m/s.
5. steadily fill the type Pouring System Design Method according to the described no air gap of claim 1, it is characterized in that: can be by in described cross gate, adding screen pack or rotating slag trap and control poring rate.
6. a no air gap steadily fills the used running gate system of type Pouring System Design Method, mainly comprises cup, and sprue that is attached thereto and cross gate; It is characterized in that: the described cup with feed opening is an eccentric structure, it is the relatively side at cup center that cast gate is located at cup, the internal orifice of its feed opening is provided with the projective table type port, and cup links to each other with a stopper rod system, and the free end of stopper rod dynamically contacts with internal orifice; Described sprue is up big and down small streamlined structure; Arc transition is adopted in sprue and cross gate corner.
7. steadily fill the used running gate system of type Pouring System Design Method by the described no air gap of claim 6, it is characterized in that: in described cross gate, add screen pack or rotation slag trap.
8. steadily fill the used running gate system of type Pouring System Design Method by the described no air gap of claim 6, it is characterized in that: the radius of corner of described sprue and cross gate corner arc transition is at least a times of cross gate diameter.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNA2003101052170A CN1552542A (en) | 2003-11-28 | 2003-11-28 | Design method and system for no air gap stable filling casting |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNA2003101052170A CN1552542A (en) | 2003-11-28 | 2003-11-28 | Design method and system for no air gap stable filling casting |
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| CN1552542A true CN1552542A (en) | 2004-12-08 |
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| CNA2003101052170A Pending CN1552542A (en) | 2003-11-28 | 2003-11-28 | Design method and system for no air gap stable filling casting |
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Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102319891A (en) * | 2011-09-13 | 2012-01-18 | 中国科学院金属研究所 | Gating system capable of effectively controlling air entrainment and slag entrainment and design method thereof |
| CN102886501A (en) * | 2012-10-09 | 2013-01-23 | 中国科学院金属研究所 | Tooling for efficiently manufacturing wide thick plate blank for wide thick plate rolling machine and manufacture method thereof |
| CN103949586A (en) * | 2014-05-22 | 2014-07-30 | 贵阳百德铸造有限公司 | Universal bottom mold for pouring precoated sand mold |
| CN108160936A (en) * | 2018-02-11 | 2018-06-15 | 常州中车汽车零部件有限公司 | A kind of small-sized volute casting mould and casting method |
| CN110918893A (en) * | 2019-12-03 | 2020-03-27 | 中国船舶重工集团公司第十二研究所 | Design method of flow-adaptive curve-shaped gravity pouring system |
| CN115647343A (en) * | 2022-10-13 | 2023-01-31 | 哈尔滨理工大学 | Liquid metal mold filling capacity evaluation method and test device |
-
2003
- 2003-11-28 CN CNA2003101052170A patent/CN1552542A/en active Pending
Cited By (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102319891A (en) * | 2011-09-13 | 2012-01-18 | 中国科学院金属研究所 | Gating system capable of effectively controlling air entrainment and slag entrainment and design method thereof |
| CN102886501A (en) * | 2012-10-09 | 2013-01-23 | 中国科学院金属研究所 | Tooling for efficiently manufacturing wide thick plate blank for wide thick plate rolling machine and manufacture method thereof |
| CN102886501B (en) * | 2012-10-09 | 2014-07-02 | 中国科学院金属研究所 | Tooling for efficiently manufacturing wide thick plate blank for wide thick plate rolling machine and manufacture method thereof |
| CN103949586A (en) * | 2014-05-22 | 2014-07-30 | 贵阳百德铸造有限公司 | Universal bottom mold for pouring precoated sand mold |
| CN108160936A (en) * | 2018-02-11 | 2018-06-15 | 常州中车汽车零部件有限公司 | A kind of small-sized volute casting mould and casting method |
| CN110918893A (en) * | 2019-12-03 | 2020-03-27 | 中国船舶重工集团公司第十二研究所 | Design method of flow-adaptive curve-shaped gravity pouring system |
| CN115647343A (en) * | 2022-10-13 | 2023-01-31 | 哈尔滨理工大学 | Liquid metal mold filling capacity evaluation method and test device |
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