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CN104190868A - Lost foam casting process - Google Patents

Lost foam casting process Download PDF

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Publication number
CN104190868A
CN104190868A CN201410496681.5A CN201410496681A CN104190868A CN 104190868 A CN104190868 A CN 104190868A CN 201410496681 A CN201410496681 A CN 201410496681A CN 104190868 A CN104190868 A CN 104190868A
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CN
China
Prior art keywords
bead
casting
casting process
lost foam
sand
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Pending
Application number
CN201410496681.5A
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Chinese (zh)
Inventor
陈凌
王琰
任琪
程晓
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
KPS Wuxi Machinery Technology Co Ltd
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KPS Wuxi Machinery Technology Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Priority to CN201410496681.5A priority Critical patent/CN104190868A/en
Publication of CN104190868A publication Critical patent/CN104190868A/en
Pending legal-status Critical Current

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Abstract

The invention discloses a last foam casting process which sequentially comprises the following steps: a, manufacturing models; b, combining the models of which the sizes and the shapes are similar to those of a cast piece into a model group, coating a fireproof layer, and drying; c, burying the dried model group into a sand box, vibrating to solid the sand box, and covering a plastic cloth; d, casting to form under the action of negative pressure; e, after the casting is completed, uncovering the plastic cloth, continuously vacuuming for minutes till the surface of the cast piece is hardened at the negative pressure the same as that of the step c, sufficiently cooling, and turning over the sand box to take out the last foam. The last foam casting process has the advantages that the tissue structure of the cast piece is changed, the crystalline grain is fine and small, the mechanical property of the cast piece is improved, the chemical components are relatively qualified, and the coating layer of the cast piece can be relatively thoroughly peeled off.

Description

A kind of lost foam casting process
Technical field
The present invention relates to the casting technique of a kind of casting technique, particularly a kind of lost foam.
Background technology
Tradition sand casting flow process, to pass through modeling, manufacture core box, arbor preparation, sprue gate preparation, join a series of technical process such as sand preparation, core sand preparation, sandbox preparation, coating preparation, coremaking moulding, mould assembling, cast, sand removal, polishing cast gate, chipping overlap, just can go out foundry goods.This processing step more complicated, because core combination in technique can cause error, also will process burr and overlap after getting core, has increased the program of mechanical treatment, and the waste product that occurs now and then, and in addition, sand removal, polishing cause the pollution of environment more.
Lost foam casting process has been a ripe technology, traditional lost foam casting process is that the bubbles model bonding similar to casting dimension shape is combined into model cluster, brush after flame retardant coating oven dry, be embedded in drystone English sandbox, through jolt ramming, cover Polypropylence Sheet, casting forming under suction function, cast complete, in the situation that Polypropylence Sheet is motionless, reduce vacuum and continue to vacuumize several minutes that (the concrete time of this extracting vacuum determines by foundry goods situation to stopping inhaling vacuum after cast(ing) surface sclerosis is shaped, object is for cast(ing) surface sclerosis is shaped), open Polypropylence Sheet, after fully cooling, mould turnover pickup.Traditional lost foam casting process is thought: in order to guarantee not crush, must be at the motionless prerequisite decline rough vacuum extracting vacuum number minute of Polypropylence Sheet, and this is the mistaken ideas that traditional lost foam casting process exists; The larger stress of the inner existence of foundry goods after the casting of tradition lost foam casting process, traditional handicraft exists stress to answer to obtain feature in order to solve foundry goods inside, and the method for employing is after casting technique completes, to carry out independent crash handling; Also have in traditional handicraft because the cooling speed of cast(ing) surface is slower, the easy ecto-entad of part residual carbon element after evaporative pattern gasification infiltrates foundry goods, causes foundry goods chemical analysis to change, and the microstructure of foundry goods changes, performance change, thus cause foundry goods undesirable.
Summary of the invention
In order to solve above-mentioned technology, have the complete technology prejudice that Polypropylence Sheet can cause crush of opening immediately of casting, problem, the invention provides a kind of lost foam casting process, has the not beneficial effect of crush.
The present invention is achieved through the following technical solutions:
A lost foam casting process, in turn includes the following steps:
Step a: modelling;
Step b: the model bonding similar to casting dimension shape is combined into model cluster, brushes flame retardant coating and dry;
Step c: the model cluster after drying is embedded in sandbox, and ram-jolt also covers Polypropylence Sheet;
Steps d: casting forming under suction function;
Step e: after casting, open Polypropylence Sheet, under the identical negative pressure with step c, continue extracting vacuum number minute to cast(ing) surface sclerosis, fully cooling, mould turnover pickup.
The bubble of described step a modelling is moulded bead and is selected expandable polystyrene resin bead, the particle diameter of the original bead of selecting be less than or equal to foundry goods minimum wall thickness (MINI W.) 1/9 ~ 1/10.
Expandable polystyrene resin bead described in prefoam: method has three kinds: hot water prefoam, steam pre-foaming and vacuum pre expansion.
After prefoam, carry out slaking: the expandable polystyrene resin bead through prefoam is placed in feed bin dry, that ventilate, removes the moisture of surface of beads, and the curing time was at 8 ~ 48 hours.
After slaking, carry out foaming: the expandable polystyrene resin bead of prefoam and slaking is filled in the die cavity of metal die and heats, bead is reexpanded, fill up the space between bead, and make mutually to merge between bead, form smooth surface, i.e. model.
In described step c, the sandbox with aspirating chamber is placed on shake table, and clamping, bed load is put in bottom, casting bed thickness more than 50 ~ 100mm, vibration ramming, molding sand is binder free, without dosing thing, water-free dry quartz sand; Place EPS model group, and train sand and fix; Add dry sand, impose vibration X, Y, tri-directions of Z simultaneously, the time is 30 ~ 60 seconds; Sandbox surface seals with plastic sheeting, with vavuum pump, will in sandbox, be pumped into certain vacuum, leans on the difference of atmospheric pressure and casting mold internal pressure that sand grains is bonded together, and maintains casting mold casting cycle and does not collapse loose.
Described step e: after cooling cleaning is cooling, sandbox is tilted to hang out foundry goods or directly from sandbox, hang out foundry goods all can, foundry goods and dry sand natural separation.
Also comprise the f step of carrying out separately crash handling.
Beneficial effect:
The first, the present invention has overcome the prejudice of prior art and has invented a kind of new technique, and the vacuum while keeping casting after opening Polypropylence Sheet continues extracting vacuum, can make not crush of sandbox.
The second, under the effect of extracting vacuum, a large amount of cold airs enter sandbox, the surface temperature rapid drawdown of foundry goods in sandbox, but foundry goods internal stability temperature is substantially constant.After several minutes, stop vacuumizing, internal heat is conducted to external diffusion by heat, and this process is equivalent to foundry goods to carry out a crash handling, has eliminated the residual stress in foundry goods, and the institutional framework of foundry goods changes, and the mechanical performance of foundry goods strengthens.What can save like this traditional handicraft carries out separately the operation of crash handling, but reach traditional handicraft simultaneously, carries out the performance after Ageing Treatment, and its technique is simple, saved production cost; Can certainly continue Ageing Treatment, further strengthen the mechanical performance of foundry goods.
The 3rd, because the shrinkage factor of lost foam paint layer and foundry goods is different, by quenching and heat conducting variation, make to form once and clash between dope layer and foundry goods, and make between them to produce gap, after mould turnover, dope layer is easy to peel off.
The specific embodiment
Below in conjunction with embodiment, the present invention is further introduced:
A lost foam casting process, in turn includes the following steps:
Step a: modelling;
Step b: the model bonding similar to casting dimension shape is combined into model cluster, brushes flame retardant coating and dry;
Step c: the model cluster after drying is embedded in sandbox, and ram-jolt also covers Polypropylence Sheet;
Steps d: casting forming under suction function;
Step e: after casting, open Polypropylence Sheet, under the identical negative pressure with step c, continue extracting vacuum number minute to cast(ing) surface sclerosis, fully cooling, mould turnover pickup.
1, bubble is moulded selecting of bead
The foam beads of lost foam casting special use has three kinds.Select expandable polystyrene resin bead (being called for short EPS); Bead feature: translucent bead, prefoam multiple 40 ~ 60, particle diameter is 0.18 ~ 0.80 millimeter, the particle diameter of the original bead of generally selecting be less than or equal to foundry goods minimum wall thickness (MINI W.) 1/9 ~ 1/10.
2, modelling
1. prefoam
EPS bead, before adding mould, first carry out prefoam, so that bead expand into certain size.Prefoam process has determined density, dimensional stability and the precision of model, is one of key link.Be applicable to the method that EPS bead gives foaming and have three kinds: hot water prefoam, steam pre-foaming and vacuum pre expansion.The bead frothing percentage of vacuum pre expansion is high, and bead is dry, applies more.
2. slaking
Through the EPS of prefoam bead, be placed on certain hour in feed bin dry, that ventilate.To make extraneous pressure balance in bead abscess, make bead there is elasticity and swelliong power again, remove the moisture of surface of beads.Curing time was at 8 ~ 48 hours.
3. foaming
The EPS bead of prefoam and slaking is filled in the die cavity of metal die, and heating, makes bead again
Inferior expansion, fills up the space between bead, and makes mutually to merge between bead, forms smooth surface, i.e. model.Before depanning, must carry out coolingly, model is cooled to below softening temperature, after model sclerosis setting, could depanning.The time that also should have the dry and dimensionally stable of model after depanning.Equipment has two kinds of the forming machines of digester (-tor) and automatic forming.
(3) model group composite variety
To process voluntarily or the bubble moulding model of outsourcing and the combination of dead head model are bonded together, formation model bunch, this combination is carried out sometimes before coating, while sometimes burying case moulding after coating preparation, carries out.It is the indispensable procedure of evaporative pattern cavityless casting.The binding material using at present: rubber latex, resin solvent and PUR and adhesive tape.
(4) mould coatings
The essential certain thickness coating of one deck that is coated with in cavityless casting bubble moulding model surface, forms casting mold inner casing.The effect of its coating is in order to improve the strength and stiffness of EPS model, improves the anti-molding sand scouring capability of model surface, and the dimensional accuracy of foundry goods is guaranteed in the distortion of model while preventing from adding model surface breakage and vibration molding and negative pressure shaping in sand process.The paint specially for disappearing cast mold of outsourcing adds water and stirs in mould wash mixer, makes it obtain suitable viscosity.Coating after stirring is put into container, by the method for soaking, brush, drenching and spraying, model group is applied.General painting twice, making coating layer thickness is 0.5 ~ 2mm.Different selected according to foundry goods alloy species, planform and size.Coating is dried at 40 ~ 50 ℃.
(5) vibration molding
Its operation comprises following operation: casting bed preparation---places EPS model---back-up sand---sealing sizing
1. casting bed preparation
Sandbox with aspirating chamber is placed on shake table, and clamping.Certain thickness bed load (general casting bed thickness is more than 50 ~ 100mm), vibration ramming are put in bottom.Molding sand is that binder free, nothing are dosed thing, water-free dry quartz sand.Ferrous metal temperature is high, can select thicker sand, and aluminium alloy adopts compared with fine sand.Molding sand is wanted Reusability after treatment.Sandbox is one side opening, be provided with the sandbox of aspirating chamber or exhaust tube, lifting or walking mechanism.
2. place EPS model
After jolt ramming, on it, according to technological requirement, place EPS model group, and train sand and fix.
3. back-up sand
Add dry sand (several sand method that adds), impose vibration (X, Y, tri-directions of Z) simultaneously, the time is generally 30 ~ 60 seconds, makes molding sand be full of each position of model, and the bulk density of molding sand is increased.
4. sealing sizing
Sandbox surface seals with plastic sheeting, with vavuum pump, will in sandbox, be pumped into certain vacuum, by the difference of atmospheric pressure and casting mold internal pressure, by together with sand grains " bonding ", maintains casting-up process and does not collapse loosely, is referred to as " negative pressure shaping.Comparatively conventional.
(6) cast displacement
The general 80 ℃ of left and right of EPS model are softening, in the time of 420 ~ 480 ℃, decompose.Catabolite has gas, liquid and solid three parts.Heat decomposition temperature is different, and three's content is different.During cavityless casting cast, under the heat effect of liquid metals, EPS model generation pyrolytic gasification, produce a large amount of gas, constantly by coating molding sand, outwards discharge, in casting mold, model and metal gap, form certain air pressure, liquid metals constantly occupies EPS modal position, pushes ahead, and the replacement process of liquid metals and EPS model occurs.The final result of displacement is to form foundry goods.It is---soon---slow that pouring operation process adopts slow.And keep continuous pouring, prevent casting process cutout.Water rear casting mold vacuum maintain 3 ~ 5 minutes after termination of pumping.Pouring temperature is higher 30 ~ 50 ℃ than the temperature of sand casting.
(7) cooling cleaning
After cooling, cavityless casting knockout is the simplest, sandbox is tilted to hang out foundry goods or directly from sandbox, hang out foundry goods all can, foundry goods and dry sand natural separation.Isolated dry sand is reused after processing.
Further preferred, also comprise the f step of carrying out separately crash handling.

Claims (8)

1. a lost foam casting process, is characterized in that, in turn includes the following steps:
Step a: modelling;
Step b: the model bonding similar to casting dimension shape is combined into model cluster, brushes flame retardant coating and dry;
Step c: the model cluster after drying is embedded in sandbox, and ram-jolt also covers Polypropylence Sheet;
Steps d: casting forming under suction function;
Step e: after casting, open Polypropylence Sheet, under the identical negative pressure with step c, continue extracting vacuum number minute to cast(ing) surface sclerosis, fully cooling, mould turnover pickup.
2. lost foam casting process according to claim 1, it is characterized in that, the bubble of described step a modelling is moulded bead and is selected expandable polystyrene resin bead, the particle diameter of the original bead of selecting be less than or equal to foundry goods minimum wall thickness (MINI W.) 1/9 ~ 1/10.
3. lost foam casting process according to claim 2, is characterized in that, expandable polystyrene resin bead described in prefoam: method has three kinds: hot water prefoam, steam pre-foaming and vacuum pre expansion.
4. lost foam casting process according to claim 3, it is characterized in that, after prefoam, carry out slaking: the expandable polystyrene resin bead through prefoam is placed in feed bin dry, that ventilate, removes the moisture of surface of beads, and the curing time was at 8 ~ 48 hours.
5. lost foam casting process according to claim 4, it is characterized in that, after slaking, carry out foaming: the expandable polystyrene resin bead of prefoam and slaking is filled in the die cavity of metal die and heats, bead is reexpanded, fill up the space between bead, and make mutually to merge between bead, form smooth surface, i.e. model.
6. lost foam casting process according to claim 1, it is characterized in that, in described step c, sandbox with aspirating chamber is placed on shake table, and clamping, bed load is put in bottom, and casting bed thickness is more than 50 ~ 100mm, vibration ramming, molding sand is that binder free, nothing are dosed thing, water-free dry quartz sand; Place EPS model group, and train sand and fix; Add dry sand, impose vibration X, Y, tri-directions of Z simultaneously, the time is 30 ~ 60 seconds; Sandbox surface seals with plastic sheeting, with vavuum pump, will in sandbox, be pumped into certain vacuum, leans on the difference of atmospheric pressure and casting mold internal pressure that sand grains is bonded together, and maintains casting mold casting cycle and does not collapse loose.
7. lost foam casting process according to claim 1, is characterized in that, described step e: after cooling cleaning is cooling, sandbox is tilted to hang out foundry goods or directly from sandbox, hang out foundry goods all can, foundry goods and dry sand natural separation.
8. according to the lost foam casting process described in claim 1 ~ 7, it is characterized in that, also comprise the f step of carrying out separately crash handling.
CN201410496681.5A 2014-09-25 2014-09-25 Lost foam casting process Pending CN104190868A (en)

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Application Number Priority Date Filing Date Title
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Application Number Priority Date Filing Date Title
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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105014012A (en) * 2015-07-27 2015-11-04 福建省神悦铸造股份有限公司 A kind of preparation technology of lost foam
CN106077478A (en) * 2016-07-30 2016-11-09 安徽全柴天和机械有限公司 A kind of process of lost foam casting vibration moulding by casting
CN107716851A (en) * 2017-09-01 2018-02-23 东风精密铸造安徽有限公司 A kind of evaporative pattern bead steam pre-foaming technique
CN108127086A (en) * 2017-12-22 2018-06-08 天津万石科技发展有限公司 A kind of application process of insulated feeder in lost foam casting
CN108262446A (en) * 2018-04-10 2018-07-10 马鞍山市麦立机械制造有限公司 A kind of production technology of the guiding frame based on cavityless casting
CN109108230A (en) * 2018-07-11 2019-01-01 马鞍山力搏机械制造有限公司 A kind of casting process of pump body cast
CN106513658B (en) * 2016-12-29 2019-03-01 北京天哲消失模铸造技术有限公司 Aluminium alloy lost foam foundry production line
CN109550900A (en) * 2018-12-18 2019-04-02 汉中燕航精工机械有限公司 A kind of casting technique of evaporative pattern
CN110102713A (en) * 2019-05-31 2019-08-09 台州巨东精密铸造有限公司 A kind of casting and pouring moulding process based on evaporative pattern

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105014012A (en) * 2015-07-27 2015-11-04 福建省神悦铸造股份有限公司 A kind of preparation technology of lost foam
CN106077478A (en) * 2016-07-30 2016-11-09 安徽全柴天和机械有限公司 A kind of process of lost foam casting vibration moulding by casting
CN106513658B (en) * 2016-12-29 2019-03-01 北京天哲消失模铸造技术有限公司 Aluminium alloy lost foam foundry production line
CN107716851A (en) * 2017-09-01 2018-02-23 东风精密铸造安徽有限公司 A kind of evaporative pattern bead steam pre-foaming technique
CN108127086A (en) * 2017-12-22 2018-06-08 天津万石科技发展有限公司 A kind of application process of insulated feeder in lost foam casting
CN108262446A (en) * 2018-04-10 2018-07-10 马鞍山市麦立机械制造有限公司 A kind of production technology of the guiding frame based on cavityless casting
CN109108230A (en) * 2018-07-11 2019-01-01 马鞍山力搏机械制造有限公司 A kind of casting process of pump body cast
CN109550900A (en) * 2018-12-18 2019-04-02 汉中燕航精工机械有限公司 A kind of casting technique of evaporative pattern
CN110102713A (en) * 2019-05-31 2019-08-09 台州巨东精密铸造有限公司 A kind of casting and pouring moulding process based on evaporative pattern

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Application publication date: 20141210