CN108057873B - Process method for casting thin-wall aluminum alloy casting at low pressure - Google Patents
Process method for casting thin-wall aluminum alloy casting at low pressure Download PDFInfo
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- CN108057873B CN108057873B CN201810071654.1A CN201810071654A CN108057873B CN 108057873 B CN108057873 B CN 108057873B CN 201810071654 A CN201810071654 A CN 201810071654A CN 108057873 B CN108057873 B CN 108057873B
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- 238000005266 casting Methods 0.000 title claims abstract description 126
- 238000000034 method Methods 0.000 title claims abstract description 40
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 19
- 239000004576 sand Substances 0.000 claims abstract description 46
- 229910052751 metal Inorganic materials 0.000 claims description 6
- 239000002184 metal Substances 0.000 claims description 6
- 238000007789 sealing Methods 0.000 claims description 5
- 239000011347 resin Substances 0.000 claims description 4
- 229920005989 resin Polymers 0.000 claims description 4
- 244000035744 Hura crepitans Species 0.000 claims description 2
- 238000012937 correction Methods 0.000 claims description 2
- 239000007769 metal material Substances 0.000 claims description 2
- 238000004519 manufacturing process Methods 0.000 abstract description 10
- 238000012827 research and development Methods 0.000 abstract description 9
- 238000009966 trimming Methods 0.000 abstract description 3
- 238000005516 engineering process Methods 0.000 description 6
- 238000000465 moulding Methods 0.000 description 4
- 239000007788 liquid Substances 0.000 description 3
- 230000003014 reinforcing effect Effects 0.000 description 3
- 239000000654 additive Substances 0.000 description 2
- 230000000996 additive effect Effects 0.000 description 2
- 238000005422 blasting Methods 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012356 Product development Methods 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 238000012797 qualification Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/04—Low pressure casting, i.e. making use of pressures up to a few bars to fill the mould
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D18/00—Pressure casting; Vacuum casting
- B22D18/08—Controlling, supervising, e.g. for safety reasons
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/30—Computing systems specially adapted for manufacturing
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention provides a process method for casting a thin-wall aluminum alloy casting at low pressure, which solves the problems of long research and development period and high research and development cost caused by continuous trimming or new manufacturing of a mold due to continuous adjustment of a product structure in a product research and development period. The method comprises the following steps: s001, establishing a three-dimensional model of the casting in three-dimensional software according to a two-dimensional drawing of the product; step S002, arranging a gating system and a riser on the three-dimensional casting model according to the process requirements, and obtaining a core body of the casting after the differences among the three-dimensional casting model, the gating system and the riser are solved on the premise of minimum sand-carrying capacity; and S003, performing core splitting and/or parting on the casting core body, and splitting the casting core body into an inner cavity sand core, an outer sand mold and a riser sand mold, wherein the inner cavity sand core is used for forming an inner cavity structure of the casting, the outer sand mold is used for forming an outer shape structure of the casting, the riser sand mold is used for accommodating a riser, and a riser and sprue seat is arranged on the outer surface of the riser sand mold.
Description
Technical Field
The invention relates to a low-pressure casting technology, in particular to a casting process of an aluminum alloy thin-wall casting.
Background
The aluminum alloy shell casting shown in FIG. 1 belongs to a typical large-size thin-wall aluminum casting, and the diameter of the aluminum alloy shell casting is phi 400mm-1200 mm. The outer surface of the product needs to be fully processed, and more reinforcing ribs, umbilicals (needing to be punched) and the like exist inside the product. In the molding process, the products are mostly produced by adopting a mold process, the casting is split along the maximum section of the casting, the outer contour is taken out by the mold, the inner cavity structure is formed by a sand core, and the inner cavity sand core is formed by a wood core box. In addition, in the product research and development period, the mold needs to be frequently modified due to product structure modification or casting process adjustment, so that the research and development cost is high and the period is long. Meanwhile, in the core assembling process, the core assembling precision is generally controlled by combining a special clamp with manual measurement, and the operation difficulty is high. The sand core manufactured by the existing core manufacturing and molding process is various, the core assembling mode is complex, the process control requirement is complex, and the requirement on the skill level of field workers is high. Meanwhile, the size of the product is difficult to control, resulting in large size error.
Disclosure of Invention
In view of the above problems, there is a need for a process for low-pressure casting of thin-wall aluminum alloy castings, so as to solve the problems of long development period and high development cost caused by continuous trimming or new manufacturing of a mold due to continuous adjustment of a product structure in a product development period, and avoid the problems of a large number of sand cores, high core assembly difficulty and low precision caused by core division and/or parting according to the product structure by adopting an additive manufacturing technology.
A process method for casting a thin-wall aluminum alloy casting at low pressure comprises the following steps:
s001, establishing a three-dimensional model of the casting in three-dimensional software according to a two-dimensional drawing of the product;
step S002, arranging a gating system and a riser on the three-dimensional casting model according to the process requirements, and obtaining a core body of the casting after the differences among the three-dimensional casting model, the gating system and the riser are solved on the premise of minimum sand-carrying capacity;
and S003, performing core splitting and/or parting on the casting core body, and splitting the casting core body into an inner cavity sand core, an outer sand mold and a riser sand mold, wherein the inner cavity sand core is used for forming an inner cavity structure of the casting, the outer sand mold is used for forming an outer shape structure of the casting, the riser sand mold is used for accommodating a riser, and a riser and sprue seat is arranged on the outer surface of the riser sand mold.
As a further limitation of the invention, snap fasteners for positioning and fixing are arranged on the matching surfaces of the inner cavity sand core, the exterior sand mold and the riser sand mold.
As a further limitation of the invention, the casting chassis matched with the mold core body is made of metal materials capable of resisting high temperature of more than 900 ℃, and the concrete structure of the casting chassis is a round or steering flat disc with a liquid lifting pipe in the middle, so that the casting chassis is repeatedly utilized, the production cost is reduced, and the production universality is facilitated. Meanwhile, the liquid lifting pipe is also a sprue, and molten metal enters a pouring system from the liquid lifting pipe to fill the casting.
The technical effect of the technical scheme is as follows: by implementing the process method for casting the thin-wall aluminum alloy casting at low pressure, the problems of long research and development period and high research and development cost caused by continuous trimming or new manufacturing of a mould due to continuous adjustment of a product structure in the research and development period of the product are solved, so that the research and development period is shortened by over 80 percent; meanwhile, the problems of large quantity of sand cores, high core assembly difficulty and low precision caused by core splitting and/or parting according to the product structure are solved by adopting an additive manufacturing technology. According to the invention, the universal pouring base is arranged, so that the production efficiency is improved, and the production cost is reduced. Through adopting the mode of core integral type somatotype, avoided the core assembling process of non-planar structure, reduced the operation degree of difficulty of core assembling process, also promoted the precision of type assembling, promoted technology yield for the qualification rate of foundry goods reaches more than 95%.
Drawings
FIG. 1 is a view of the thin-walled aluminum alloy casting of the present invention;
FIG. 2 is a schematic view of the gating system and riser arrangement of the present invention;
FIG. 3 is a schematic illustration of the core assembly of the present invention;
FIG. 4 is a blasting diagram of a first parting scheme of the invention;
fig. 5 is a blasting diagram of a second parting scheme of the invention.
In the figure, 1-sprue; 2-horizontal pouring channel; 3-inner pouring channel; 4-a riser; 5-pouring a chassis; 5A-a riser tube; 5B-bottom support; 6-inner cavity sand core; 6A-transverse pouring channel type; 6B-inner cavity column core; 7-molding in a shape of sand; 8-riser sand molding; 8A-a riser cap; 8B-riser core; 9A-a first parting surface; 9B-a second parting plane; 10-inner cavity sand core with window; 11-a half-type external sand mold.
Detailed Description
In order to more clearly illustrate the technical solution of the present invention, the detailed description will be given according to the embodiments of the drawings, and it is obvious that the drawings in the following description are some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
As shown in fig. 1, the structure is a cylindrical body with an inner cavity provided with a reinforcing rib, and the outer circumferential wall of the cylindrical body is provided with a window. The columnar casting adopts a low-pressure casting technology, and the first parting scheme is as follows:
step S101, establishing a three-dimensional model of a columnar casting in three-dimensional software according to a product two-dimensional drawing;
step S102, arranging a gating system and a riser on the three-dimensional model of the columnar casting according to process requirements, and obtaining a core body of the columnar casting after calculating differences with the three-dimensional model of the columnar casting, the gating system and the riser on the premise of minimum sand-carrying capacity;
step S103, performing core splitting and/or parting on the columnar casting core body, wherein a surface perpendicular to the axial direction of the casting along the upper edge of the window on the columnar casting is a first parting surface 9A, a second parting surface 9B is formed along the joint surface of the sprue and the cross gate, the columnar casting core body is split into three parts by the first parting surface 9A and the second parting surface 9B, the three parts are respectively an inner cavity sand core 6, an outer shape sand mold 7 and a riser sand mold 8, the inner cavity sand core 6 comprises an inner cavity structure of the columnar casting, the cross gate 2 and the joint section of the sprue 1 and the cross gate 2, the outer shape sand mold 7 comprises the outer shape structure of the columnar casting and the inner gate 3, and the riser sand mold 8 is provided with a riser 4 connected with the inner gate 3.
Preferably, the machining amount can be set on the to-be-machined surface of the product according to the technical quality requirement on the three-dimensional model of the cylindrical casting, and the process correction amount is set on the key thin-wall part. And half of the wall thickness of the key thin-wall part is 3mm-12 mm.
Preferably, the gating system adopts a low-pressure casting system, and particularly, the sprue 1 is positioned at the circle center of the bottom of the cylindrical casting core body; a plurality of transverse runners 2 are uniformly distributed along the radial direction of the bottom of the cylindrical casting core body; and a plurality of ingates 3 are distributed along the axial direction of the cylindrical casting core body from one end of the horizontal pouring channel 2 far away from the sprue 1 and are communicated to the top of the cylindrical casting core body.
Preferably, a corresponding riser 4 is arranged at the end of each ingate 3 positioned on the top surface of the cylindrical casting core body, so that molten metal is stamped, a product can be filled, and the defects of shrinkage cavity, shrinkage sink and the like are avoided.
Preferably, the riser sand mold 8 can also be set as a riser core 8B and a riser cover 8A, so as to facilitate the core assembly, enable the riser to be well aligned with the ingate 3, and facilitate the smooth flow of molten metal. And a positioning core head is arranged on the riser core 8B, so that the riser sand mold 8 and the inner cavity sand core 6 are convenient to be matched with each other.
Preferably, when the cavity core 6 affects the arrangement of the chill, the cavity core 6 may be split into a cavity cylinder core 6B and a runner mold 6A.
Preferably, a fit clearance of 0.2mm-1.0mm is arranged among the inner cavity sand core 6, the exterior sand mold 7 and the riser sand mold 9, and a sealing strip is arranged at the fit clearance in the core assembling process.
Preferably, a chilling block accommodating cavity is reserved on the cylindrical casting core body, wherein chilling blocks need to be placed on the cylindrical casting core body, and a fit clearance of 0.3mm-0.5mm is reserved between the chilling block accommodating cavity and the chilling block.
Preferably, a snap fastener structure for matching and positioning is arranged on the runner type 6A of the inner cavity sand core 6.
The forming and pouring process of the columnar casting is as follows:
1) placing the inner cavity sand core on a casting chassis;
2) forming the exterior sand mold on the inner cavity sand core through a snap fastener positioning structure;
3) buckling a riser sand mold on the upper parts of the exterior sand mold and the inner cavity sand core to complete the assembly of the whole columnar casting core body;
4) sealing the fit clearance among the inner cavity sand core, the riser sand mold and the exterior sand mold by using a sealing strip;
5) and placing the sealed cylindrical casting core body and the pouring chassis in a corresponding sand box, carrying out resin sand back flow, and moving the whole box body to a pouring area to be poured after the resin sand is hardened.
Preferably, the molten metal is injected into a pouring system of the columnar casting core body through a riser tube at a low pressure of 0.3MPa to 0.7MPa, and the pressure is maintained for 15min to 30min, so that pouring of the columnar casting is completed.
As shown in fig. 1, the structure is a cylindrical body with an inner cavity provided with a reinforcing rib, and the outer circumferential wall of the cylindrical body is provided with a window. The cylindrical casting adopts a low-pressure casting technology, and the second parting scheme is as follows:
step S201, establishing a three-dimensional model of a columnar casting in three-dimensional software according to a product two-dimensional drawing;
step S202, arranging a gating system and a riser on the three-dimensional model of the columnar casting according to process requirements, and obtaining a core body of the columnar casting after calculating differences with the three-dimensional model of the columnar casting, the gating system and the riser on the premise of minimum sand-carrying capacity;
step S203, performing core separation and/or parting on the cylindrical casting core body, taking out the core of the whole inner cavity of the cylindrical casting, forming an inner cavity sand core 10 with a window in a runner mold where a runner structure is located, cutting the sand mold of the cylindrical casting appearance structure into two symmetrical half-shape 11 along the symmetrical axis of the window of the cylindrical casting, wherein the two symmetrical half-shape 11 can effectively wrap the structure of the window part, and the cap 8A is directly buckled on the inner cavity sand core 10 with the window.
According to the second parting scheme, the ingate 3 and the riser 4 can be integrally formed, so that the phenomenon that the molten metal is turbulent due to the misalignment of the two ingates, and the surface quality of a casting is poor is avoided.
The group type process of the second scheme is as follows:
1) placing a casting chassis 5 on a combined platform, and positioning an inner cavity sand core 10 with a window on the casting chassis 5 through a positioning male and female buckle structure;
2) buckling the half-shaped profile 11 on the cavity sand core 10 with the window through a positioning male-female buckle;
3) and buckling the cap 8A on the inner cavity sand core 10 with the window through the positioning male and female buckles to complete the assembly of the whole cylindrical casting core body.
Finally, it should be noted that: the above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; and the modifications or the substitutions do not make the essence of the corresponding technical solutions depart from the scope of the technical solutions of the embodiments of the present invention.
Claims (8)
1. The process method for casting the thin-wall aluminum alloy casting at low pressure is characterized in that the parting scheme of the thin-wall aluminum alloy casting at low pressure specifically comprises the following steps:
s101, establishing a three-dimensional model of a columnar casting in three-dimensional software according to a product two-dimensional drawing;
s102, arranging a pouring system and a riser on the three-dimensional model of the columnar casting according to process requirements, and obtaining a core body of the columnar casting after calculating differences with the three-dimensional model of the columnar casting, the pouring system and the riser on the premise of minimum sand-carrying capacity;
s103, splitting and/or parting the core body of the columnar casting, wherein the surface of the upper edge of a window on the columnar casting, which is perpendicular to the axial direction of the casting, is a first parting surface (9A), the surface of the upper edge of the window on the columnar casting is a second parting surface (9B), the first parting surface (9A) and the second parting surface (9B) split the core body of the columnar casting into three parts, namely an inner cavity sand core (6), an outer shape sand mold (7) and a riser sand mold (8), the inner cavity sand core (6) comprises an inner cavity structure of the columnar casting, a cross gate (2), a straight gate (1) and a cross gate (2) connecting section, the outer shape sand mold (7) comprises the outer shape structure and the inner gate (3) of the columnar casting, and risers (4) connected with the inner gate (3) are arranged on the riser sand mold (8).
2. The process method for casting the thin-wall aluminum alloy casting at the low pressure according to claim 1, wherein snap fasteners for positioning and fixing are arranged on the matching surfaces of the cavity sand core (6), the exterior sand mold (7) and the riser sand mold (8).
3. A process for low pressure casting of thin-walled aluminum alloy castings according to claim 2, wherein the surface to be machined of the cylindrical castings is provided with a process allowance and the critical thin-walled portions of the cylindrical castings are provided with a process correction amount.
4. The process method for casting the thin-wall aluminum alloy casting at low pressure according to claim 3, wherein the gating system adopts a low-pressure casting system, and particularly a sprue (1) is positioned at the position of the circle center of the bottom of the cylindrical casting core body; a plurality of transverse pouring channels (2) are uniformly distributed along the radial direction of the bottom of the cylindrical casting core body; and a plurality of ingates (3) are distributed along the axial direction of the core body of the columnar casting from one end of the horizontal pouring channel (2) far away from the straight pouring channel (1) and are communicated to the top of the core body of the columnar casting, and corresponding risers (4) are arranged at the outlet of the ingate (3) at the top of the core body of the columnar casting.
5. The process for the low pressure casting of thin-walled aluminum alloy castings according to claim 4, characterized in that the riser sand molds (8) are set up as riser cores (8B) and riser covers (8A), and the cavity sand cores (6) are divided into cavity column cores (6B) and transverse runner molds (6A).
6. The process for low pressure casting of thin wall aluminum alloy castings according to claim 5, wherein the assembling and pouring of the columnar castings is performed by:
firstly, placing the inner cavity sand core (6) on a casting chassis (5);
secondly, forming the exterior sand mold on the inner cavity sand core (6) through a snap fastener positioning structure;
thirdly, buckling a riser sand mold (8) on the upper parts of the exterior sand mold (7) and the cavity sand core (6) to complete the assembly of the whole columnar casting core body;
fourthly, sealing the fit clearance among the inner cavity sand core (6), the riser sand mold (8) and the exterior sand mold (7) by using a sealing strip;
and fifthly, placing the sealed cylindrical casting core body and the pouring chassis into a corresponding sand box, carrying out resin sand back flow, and moving the whole box body to a pouring area to be poured after the resin sand is hardened.
7. The process for casting thin-walled aluminum alloy castings at low pressure according to claim 6, characterized in that the casting base plate (5) is made of a metal material capable of withstanding high temperatures above 900 ℃, and has a circular or square flat plate with a liquid-lifting tube in the middle.
8. The process for low pressure casting of thin-walled aluminum alloy castings according to claim 7, wherein molten metal is injected into the gating system of the core of the columnar casting through a lift tube (5A) at a low pressure of 0.3MPa to 0.7MPa, and the pressure is maintained for 15min to 30min, thereby completing the pouring of the columnar casting.
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| CN201810071654.1A CN108057873B (en) | 2018-01-26 | 2018-01-26 | Process method for casting thin-wall aluminum alloy casting at low pressure |
| CN202010623881.8A CN111659876B (en) | 2018-01-26 | 2018-01-26 | Process method for casting thin-wall aluminum alloy casting at low pressure |
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| CN201810071654.1A CN108057873B (en) | 2018-01-26 | 2018-01-26 | Process method for casting thin-wall aluminum alloy casting at low pressure |
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| CN108480560B (en) * | 2018-06-20 | 2020-12-18 | 中国航发南方工业有限公司 | Casting shape adjusting method and wax mold die set for adjusting casting shape |
| CN110695338A (en) * | 2018-07-10 | 2020-01-17 | 上海中振有色金属铸造有限公司 | Process method for casting thin-wall casting at low pressure |
| CN109676085B (en) * | 2019-01-23 | 2020-09-08 | 共享智能铸造产业创新中心有限公司 | Molding method of shell casting sand mold |
| CN110681846A (en) * | 2019-09-30 | 2020-01-14 | 山西江淮重工有限责任公司 | Horizontal modeling vertical differential pressure pouring device and pouring method for aluminum alloy special-shaped structural part |
| CN110640082B (en) * | 2019-11-08 | 2021-04-30 | 徐飞祥 | A kind of sand box casting method |
| CN111515377B (en) * | 2020-05-29 | 2022-05-03 | 中国航发南方工业有限公司 | Complex thin-wall aluminum-magnesium alloy casting and casting method thereof |
| CN112719225A (en) * | 2020-12-31 | 2021-04-30 | 四川共享铸造有限公司 | Sand core of lubricating oil cooler shell casting |
| CN113102690A (en) * | 2021-04-06 | 2021-07-13 | 洛阳乾中新材料科技有限公司 | Design method of casting mold |
| CN114012034B (en) * | 2021-10-28 | 2025-04-29 | 扬州峰明光电新材料有限公司 | Flaskless casting method for manufacturing thin-walled aluminum alloy castings |
| CN113976856A (en) * | 2021-10-29 | 2022-01-28 | 福建华威钜全精工科技有限公司 | Low-pressure casting method for improving air holes of auxiliary frame bushing |
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| CN106334780A (en) * | 2015-07-08 | 2017-01-18 | 共享装备有限公司 | Method for producing sand mold for cylinder cover through modularization |
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| Publication number | Publication date |
|---|---|
| CN108057873A (en) | 2018-05-22 |
| CN111659876A (en) | 2020-09-15 |
| CN111659876B (en) | 2022-04-19 |
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