CN109175236A - The tapered whole shell section casting and molding method of large thin-wall aluminum alloy round - Google Patents
The tapered whole shell section casting and molding method of large thin-wall aluminum alloy round Download PDFInfo
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- CN109175236A CN109175236A CN201811069451.5A CN201811069451A CN109175236A CN 109175236 A CN109175236 A CN 109175236A CN 201811069451 A CN201811069451 A CN 201811069451A CN 109175236 A CN109175236 A CN 109175236A
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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
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/09—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
- Mold Materials And Core Materials (AREA)
Abstract
The invention discloses a kind of tapered whole shell section casting and molding methods of large thin-wall aluminum alloy round, using rising pouring clearance type casting system, aluminium alloy bottom filling anti-gravity is carried out in furan resin-sand entirety sand mold according to the pre-designed drawing of rough casting and squeezes casting, obtains whole shell section casting；Solution treatment, T6 quenching, ageing treatment, roughing and finishing are carried out to whole shell section casting, obtain the tapered whole shell section of large thin-wall aluminum alloy round.The present invention is effectively controlled the deformation of each process procedure of the tapered whole shell section of large thin-wall aluminum alloy round, ensure that aerodynamic configuration, the shell section metal bearing layer evenness of wall thickness of product, the key technical index such as shell section overall weight mass center；The serial key technology in the tapered whole shell section hot investment casting molding of large thin-wall aluminum alloy round and process is effectively captured, the overall quality that ensure that the tapered whole shell section precise forming processing and manufacturing of large thin-wall aluminum alloy round, shortens the manufacturing cycle while reducing manufacturing cost.
Description
Technical field
The application belongs to casting technique preparation parts technical field, and in particular to a kind of large thin-wall aluminum alloy round is tapered
Whole shell section casting and molding method.
Background technique
Large thin-wall aluminium alloy cylinder outer race section casting, casting process is larger since alloy itself is shunk, the casting of casting
Make that stress is very big, it is many phenomenon that leading to the dimension overproof of cast product, finally scrap to produce the deformation of medium casting, especially pair
In the whole shell section casting of whole sand casting, the inner mold face of product is not reprocessed and can not be processed yet after monoblock cast, in inner mold
Face does not process and only processes on the basis of outer mold surface, it is ensured that final shape integrality, the uniformity of wall thickness, quality for guaranteeing product
The tolerance of mass center, casting difficulty is bigger, and therefore, the casting process Deformation control of casting becomes the pass of control casting deformation
Key technology.
In addition, large thin-wall aluminium alloy cylinder outer race section casting needs to be heat-treated after casting, therefore, heat treatment process is controlled
Deformation it is even more important because the size after heat treatment determines the final size of casting, in the same of control casting process
When, it is also contemplated that the deformation of control heat treatment process, this needs take in from process means, design reasonable, feasible
Casting and molding method.
Summary of the invention
In order to solve the above technical problems, the present invention provides a kind of tapered whole shell sections of large thin-wall aluminum alloy round to be cast as
Type method squeezes casting by note formula anti-gravity and heat-treatment distortion controls technology method, is effectively controlled large size
The deformation of each process procedure of thin-wall aluminum alloy pyramid type entirety shell section.
Realize that technical solution used by the object of the invention is, a kind of tapered whole shell section casting of large thin-wall aluminum alloy round
Forming method includes the following steps:
(1) whole shell section casting and forming: rising pouring clearance type casting system is used, according to the pre-designed drawing of rough casting in furane resins
Aluminium alloy bottom filling anti-gravity is carried out in sand entirety sand mold squeezes casting；
Ensure that the temperature in casting furnace is greater than 40 DEG C before casting, carries out the casting furnace preheating and drying, and described in control
Humidity is less than 80% in casting furnace；The temperature of the aluminum alloy melt is controlled when casting at 680 DEG C~720 DEG C, squeeze pressure is greater than
0.1Mpa, stamp time are 20s~40s, and dwell pressure is 0.1MPa~0.12MPa, and the dwell time is 250s~350s；Casting
Afterwards after furnace temperature drops to room temperature, blow-on after standing 4 hours obtains the whole shell section casting；
(2) solution treatment, T6 quenching and ageing treatment whole shell section heat treatment: are carried out to the whole shell section casting；
(3) whole shell section processing: roughing and finishing are carried out to the whole shell section casting, obtain the large thin-wall
The tapered whole shell section of aluminum alloy round.
Further, in step (1), the aluminium alloy is ZL114A high strength alumin ium alloy, the ZL114A high strength alumin ium alloy
It prepares with the following method:
Using smart Al ingot and Al-Si, Al-Cu, Mg and Ti-B intermediate alloy alloyage of refined aluminium founding；Nickel member is added
Element, and aluminium-strontium master alloy improvement morphology of eutectic silicon, optimized alloy constituent content is added；It is refined using high-purity argon gas, obtains institute
State ZL114A high strength alumin ium alloy；
The weight percent of the chemical component of the ZL114A high strength alumin ium alloy are as follows: Si content is 6.5%~7.5%；Cu
Content is 1%~3%；Mg content is 0.45%~0.75%；Ti+Ni total content is 0.05%~0.1%；B content is
0.05%~0.1%；Sr content is less than 0.01%；Total impurities≤0.75%, wherein major impurity Fe content < 0.1%；It is remaining
Amount is Al.
Further, in step (1), the pre-designed drawing of rough casting specifically: design length shrinking percentage be 0.8% ±
0.05%, shrinkage in width rate is 0.8% ± 0.05%, and high shrinkage rate is 0.85% ± 0.05%；Designing cast outer mold surface list
Side surplus is greater than 6mm, and axially unilateral surplus is greater than 8mm to casting.
Further, in step (1), the furan resin-sand entirety sand mold makes with the following method:
Inner mold mold and exterior mold are processed based on default geometric dimension；
Interior model sand mold is manufactured using founding based on inner mold mold, outer model sand mold, institute are manufactured using founding based on exterior mold
The formwork thickness for stating outer model sand mold is greater than 200mm；
The interior model sand mold and the outer model sand mold are assembled, the furan resin-sand entirety sand mold is obtained.
It is further, described based on default geometric dimension processing inner mold mold and exterior mold, comprising:
Inner mold mold block and exterior mold block are processed based on default geometric dimension；
The inner mold mold block was passed through and was located by connecting with axial assembling combination for the inner mold mold, by the external form
Mold block, which passed through, to be located by connecting with axial assembling combination as the exterior mold；The mistake is located by connecting specially using 1
Stub cooperates 2 or more auxiliary pins to be located by connecting；
The inner mold mold block for constituting the grid ribs position of the inner mold mold is made of furan resin-sand, manufactured
Furan resin-sand inner mold mold block surface sprayed coating.
Further, described that interior model sand mold is manufactured using founding based on inner mold mold in step (1), it is based on exterior mold
After manufacturing outer model sand mold using founding, the furan resin-sand entirety sand mold production method further include:
In the resin that the external coating of the interior model sand mold is mixed by the scouring sand and PEPSET resin of 70~140 mesh
Sand；
It is used quick drying paint brushing 2~3 times after molding in the whose surfaces of the furan resin-sand entirety sand mold, after drying
It polishes.
Further, in step (1), it is described the interior model sand mold and the outer model sand mold are assembled before, the furan
Furane resins sand entirety sand mold production method further include:
3-D scanning detection is carried out to the furan resin-sand entirety sand mold: respectively to the interior model sand mold and the external mold
Sand mold carries out 3-D scanning detection, and the outer model sand mold is detected using stock size, and examination criteria is to ensure to cast in whole sand mold
In the case where making whole shell section casting contraction, the machining allowance of the entirety shell section casting shape is meeting the large thin-wall aluminium
It is small as far as possible under the premise of alloy pyramid type entirety shell section profile tolerance, to reduce the subsequent whole shell section process-cycle；
The point cloud of the interior model sand mold three-dimensional camera shooting scanning and the interior model sand mold theory three-dimensional model are fitted pair
Than fit approach uses best fit mode, by red and yellow height in the color point cloud atlas after the interior model sand mold fitting
Point region is removed by way of manual grinding or cutting, it is ensured that the interior model sand mold profile tolerance and theory three-dimensional model 95%
The region of the above area is consistent.
Further, described that the whole shell section casting is carried out at solution treatment, T6 quenching and timeliness in step (2)
Reason, comprising:
The whole shell section casting and heat treatment tooling are carried out positioning assembly, the material of the heat treatment tooling by (2-1)
And the material of connecting pin used in positioning assembly is the aluminium alloy with the whole shell section casting same material；
(2-2) carries out the detection of first time 3-D scanning to the whole shell section casting, records the whole shell section casting
External form surface profile, and the benchmark as deformation after unloading detection；
(2-3) carries out solution treatment to the whole shell section casting and T6 is quenched；
(2-4) carries out second of 3-D scanning detection to the whole shell section casting, with the whole shell section casting inner mold
It on the basis of face, is detected using best fit mode, will test mould of the result first with first time 3-D scanning detection
Type is compared, to judge whether the solution treatment and T6 quenching technical and heat treatment tooling design are reasonable, together
Whether step deforms after judging the whole shell section casting and heat treatment tooling positioning assembly；
(2-5) removes the heat treatment tooling, then carries out the detection of third time 3-D scanning to the whole shell section casting,
The scanning result that the scanning result that the third time 3-D scanning detects is detected with the first time 3-D scanning is compared,
To detect the deflection of the whole shell section heat treating castings；The scanning that further the third time 3-D scanning is detected
As a result the theoretical target values with the whole shell section casting compare, and check and accept as final casting deflection and geometric dimension
Judgment basis；
(2-6) carries out ageing treatment to the whole shell section casting；
(2-7) carries out the 4th 3-D scanning detection to the whole shell section casting, and the 4th 3-D scanning is examined
The scanning result that the scanning result of survey is detected with the third time 3-D scanning compares, to detect the whole shell section
The deflection of cast part age processing；
(2-8) carries out X-ray and fluoroscopy to the whole shell section casting, judges whether deposit in the whole shell section casting
Susong, shrinkage cavity, crackle defect, and whether carry out repairing measures according to the defect dipoles, the repairing measures include: casting
The apparent micro-crack of part is eliminated by polishing, and apparently open shrinkage cavity can be eliminated casting by repair welding, or carries out stop hole
Evade the diffusion of crackle.
Further, in step (2), the solution treatment includes:
The whole shell section casting is warming up to 520 DEG C first, keeps the temperature 2h at a temperature of 520 DEG C, then by the whole shell
Section casting is warming up to 538 DEG C, comes out of the stove after keeping the temperature 8h at a temperature of 538 DEG C；
The T6 is quenched
It is quenched in aluminum alloy quenching liquid, the whole shell section casting is transferred to by liquid with the speed less than 20s, it is described whole
Body shell section casting using up and down it is vertical enter aqueous, the temperature of the aluminum alloy quenching liquid is not less than 70 DEG C；
The ageing treatment includes:
Artificial aging processing is carried out to the whole shell section casting in desk-top drying box, by the whole shell section casting liter
Temperature comes out of the stove after heat preservation 8h to 165 DEG C and is air-cooled to room temperature.
Further, described that roughing and finishing are carried out to the whole shell section casting in step (3), it obtains described
The tapered whole shell section of large thin-wall aluminum alloy round, comprising:
Reference measurement before (3-1) entirety shell section Mechanical processing of casting:
The levelling described whole shell section casting housing rear end face (3-1-1), is processed light-exposed；(3-1-2) is then with the entirety
On the basis of shell section casting inner mold face, crosses, determine on the cross rectangle technique boss of the back-end box of the whole shell section casting
Center；Cross rectangle technique boss described in (3-1-3) roughing；
The 3-D scanning of (3-2) entirety shell section casting and detection:
(3-2-1) determines detection coordinate system with the machined rear end face and the cross rectangle technique boss
O1xyz scans the whole shell section casting shell inner mold face and outer mold surface；(3-2-2) is with the whole shell section casting inner mold face
On the basis of, the scan model and theoretical model that scanning is obtained carry out best fit, analyze the whole shell section casting inner mold face
Profile tolerance, external form surface profile and end face plane degree；The machining allowance of (3-2-3) detection whole shell section casting is distributed feelings
Condition；(3-2-4) determines the rear end face, the cross rectangle technique boss and the detection coordinate after the best fit
It is the positional relationship of O1xyz；
(3-3) adaptive machining roughing standard:
(3-3-1) is face-up by the rear end, rear end face described in centering and the cross rectangle technique boss, determines inspection
Survey coordinate system O1xyz；(3-3-2) carries out coordinate system biasing with the rapport that the best fit determines, determines actual processing
Coordinate system O2xyz；Rear end face described in (3-3-3) Milling Process, made allowance 2mm, and coordinate the whole shell section cast-internal ring
Distance of the type grid ribs center away from the whole shell section casting front end face and rear end face；Entirety shell described in (3-3-4) Milling Process
Section casting rear end inner mold profile, single side made allowance 2mm；(3-3-5) processes the dowel hole on the rear end face, made allowance 2mm；
(3-4) is according to roughing standard roughing shell shape；
(3-4-1) is positioned with the rear end face and the dowel hole, before entirety shell section casting described in Milling Process
End face, made allowance 2mm；Entirety shell section casting shell shape described in (3-4-2) milling, unilateral made allowance are not less than 1.5mm；(3-
4-3) all shape windows and rudderpost hole characteristic of entirety shell section casting described in roughing, unilateral made allowance are not less than 2mm；
(3-5) size detection and first time 3-D scanning:
(3-5-1) detects the size of the whole shell section casting after roughing using large-scale vernier caliper and template；(3-5-
2) 3 D detection method is used, on the basis of the rear end face and the dowel hole, detects the whole shell section casting shell
Internal machined surface profile degree, external form surface profile, end face plane degree geometric tolerance；
(3-6) is heat-treated artificial aging destressing:
Heating furnace is warming up to setting process parameters range by (3-6-1), and the entirety shell section casting is vertical with bottom plate tooling
It is placed into furnace；(3-6-2) carries out artificial aging, continues 8h using 150 DEG C of furnace temperature duration 4h, or using 120 DEG C of furnace temperature；
It is air-cooled after (3-6-3) described whole shell section casting furnace cooling；
(3-7) second of 3-D scanning geometry detection:
The whole shell section casting is placed on workbench by (3-7-1), rear end face described in centering and the positioning pin
3-D scanning coordinate system O3xyz is established in hole；(3-7-2) carries out inner mold face 3-D scanning to the whole shell section casting and carries out
Points cloud processing；(3-7-3) compares a cloud and the theoretical model, analyzes the whole shell section casting deformation dimensional conditions
Distribution, and carry out deformation tendency analysis；Deformation of (3-7-4) comparison whole shell section casting before and after artificial aging,
According to batch deformation, judge whether to carry out artificial aging deformation constraint using heat treatment tooling, judgment basis is inner mold face
Profile tolerance deforms deviation and is less than 0.3mm；
(3-8) coordinates to process smart benchmark according to the uniformity requirement of inner mold surface profile and wall thickness:
(3-8-1) judges the uniformity of inner mold face surplus according to each face surplus in the whole shell section casting inner mold face, with institute
It states and is fitted the scan model of second of 3-D scanning again with the theoretical model on the basis of inner mold face, after determining fitting
The amount of bias of coordinate system；(3-8-2) carries out coordinate system biasing with the amount of bias, determines finishing coordinate system O4xyz, processes institute
Rear end face is stated, surplus is removed, is worked into design size；(3-8-3) processes the rear end inner mold profile to design size；(3-8-
4) connecting hole on the dowel hole and the rear end face is processed to design size；
(3-9) finishes shell outer mold surface and interior surface-type feature according to smart benchmark:
(3-9-1) is smart benchmark with the rear end face and the dowel hole, finish the front end face and it is described before
End-face hole on end face is to design size；(3-9-2) finishing whole shell section casting front end inner mold profile and inner mold are special
Window is levied to design size；(3-9-3) finishes pin hole on the front end face and connecting hole to design size；(3-9-4) essence
It processes outer mold surface and shape is sunk；Rudderpost, high-precision porous and the window of (3-9-5) finishing whole shell section casting
To design size；
(3-10) detects finishing back casing:
(3-10-1) finishes the linear dimension of back casing using conventional method detection；(3-10-2) with the rear end face and
The dowel hole is smart benchmark, detects finishing back casing inner mold surface profile and outer mold surface using 3-D scanning detection method
Profile tolerance；(3-10-3) is smart benchmark with the rear end face and the dowel hole, using rudderpost described in three-dimensional coordinates measurement, described
The dimensional tolerance and geometric tolerance of high-precision porous.
As shown from the above technical solution, the tapered whole shell section casting and forming side of large thin-wall aluminum alloy round provided by the invention
Method carries out whole sand casting using furan resin-sand, it has effectively evaded large thin-wall aluminium alloy entirety shell section casting and melts
The shortcomings that mould monoblock cast and metal mold high-pressure casting molding or the not achievable disadvantage of metal mold gravitational casting, and furan
Furane resins sand entirety sand mold can quickly absorb the heat in casting cooling procedure.
Casting technique uses rising pouring clearance type casting system, and casting mode squeezes casting, casting using bottom filling anti-gravity
Before ensure that temperature in casting furnace is greater than 40 DEG C, carry out casting furnace preheating and drying, and control in casting furnace humidity less than 80%；
The temperature of aluminum alloy melt is controlled when casting at 680 DEG C~720 DEG C, squeeze pressure is greater than 0.1Mpa, and the stamp time is 20s~40s,
Dwell pressure is 0.1MPa~0.12MPa, and the dwell time is 250s~350s.Compared to existing large thin-wall aluminium alloy tubular
Shell section casting method squeezes casting mode using rising pouring clearance type casting system cooperation bottom filling anti-gravity, and stamp is more complete,
The defects of having evaded many loose shrinkage cavities with pressure casting simultaneously, the crackle being likely to occur when whole sand casting, place are evaded
Pine, shrinkage cavity entirety sand casting defect, at the same evaded after casting system solidification that rigidity is too strong or rigidity is excessively weak and after causing
The large deformation risk in the stages such as continuous heat treating castings, casting system removal.
Whole shell section heat treatment process successively uses solution treatment, T6 quenching and ageing treatment, there is alloy property
Effect improves, and obtains maximum solid solution effect, and casting deformation is small.
Detailed description of the invention
Fig. 1 is the process flow of the medium-and-large-sized thin-wall aluminum alloy pyramid type entirety shell section casting and molding method of the embodiment of the present invention
Figure；
Fig. 2 is the three-dimensional structure diagram of whole shell section casting in the embodiment of the present invention；
Fig. 3 is the complete section structure chart of whole shell section casting in the embodiment of the present invention；
Description of symbols: 1- entirety shell section casting, 11- grid ribs, 12- rear end face, 13- front end face.
Specific embodiment
In order to make the application the technical staff in the technical field be more clearly understood that the application, with reference to the accompanying drawing,
Technical scheme is described in detail by specific embodiment.
In embodiments of the present invention, the tapered whole shell section casting and molding method of a kind of large thin-wall aluminum alloy round, for casting
Make the tapered whole shell section of large thin-wall aluminum alloy round, the structure of the tapered whole shell section of the large thin-wall aluminum alloy round as shown in Fig. 2,
A plurality of grid ribs 11 are distributed on whole 1 inner mold face of shell section casting, the rectangle net of grid ribs and straight line including circular annular form
Lattice muscle.The casting uses ZL114A high strength alumin ium alloy, and the technology major being related to has ZL114A high strength alumin ium alloy shell section entirety sand mold
Casting and forming, the control of ZL114A high strength alumin ium alloy casting shell section heat-treatment distortion, ZL114A high strength alumin ium alloy cast shell numerical control
Machining deformation control, three-dimensional digital camera-shooting scanning detection technique etc. belong to the molding of Alternative cooperated integration precision manufactureing and become
Shape control method.
As shown in Figure 1, the tapered whole shell section casting and molding method of the large thin-wall aluminum alloy round include successively execute as
Lower step S100~S300:
S100, whole shell section casting and forming: rising pouring clearance type casting system is used, according to the pre-designed drawing of rough casting in furans tree
Aluminium alloy bottom filling anti-gravity is carried out in rouge sand entirety sand mold squeezes casting；
Ensure that the temperature in casting furnace is greater than 40 DEG C before casting, carries out casting furnace preheating and drying, and control in casting furnace
Humidity is less than 80%；The temperature of aluminum alloy melt is controlled when casting at 680 DEG C~720 DEG C, squeeze pressure is greater than 0.1Mpa, when stamp
Between be 20s~40s, dwell pressure be 0.1MPa~0.12MPa, the dwell time be 250s~350s；It is dropped to after casting in furnace temperature
After room temperature, blow-on after standing 4 hours obtains whole shell section casting；
S200, whole shell section heat treatment: solution treatment, T6 quenching and ageing treatment are carried out to whole shell section casting；
S300, whole shell section processing: roughing and finishing are carried out to whole shell section casting, obtain large thin-wall aluminium alloy
Pyramid type entirety shell section.
According to material property, space scale, integral rigidity, the weight of the tapered whole shell section product of large thin-wall aluminum alloy round
The structure features such as mass center, design basis requirement, in conjunction with the whole sand casting process of AL-SI system ZL114A aluminium alloy, selection
Suitable entirety sand mould casting method.The present embodiment carries out whole sand casting using furan resin-sand, it effectively evades
The shortcomings that large thin-wall aluminium alloy entirety shell section casting melts mould monoblock cast and metal mold high-pressure casting molding or metal mold
The not achievable disadvantage of gravitational casting.It is whole according to design requirement on the basis of correct selection whole sand casting molding mode
The inner mold face of product is not reprocessed and can not be processed yet after body casting, on the basis of inner mold face does not process and only processes outer mold surface,
The final shape integrality for guaranteeing product, the uniformity of wall thickness, quality center of mass tolerance；The design of the pre-designed drawing of rough casting according to
According to the shrinkage character of above-mentioned requirements combination casting, guarantee each profile tolerance of a surface of outer mold surface, flatness, the depth of parallelism, symmetry, coaxial
The geometric dimensions such as width, height, the wall thickness of position degree and reinforcing rib of degree and the intracavitary reinforcing rib of type (grid ribs), in conjunction with casting
When aluminium alloy AL-SI based material entirety sand casting the characteristics of anisotropy, length, width and height (cartesian coordinate X, Y, Z tri- are designed
Direction or according to corresponding circular cylindrical coordinate or spherical coordinates) be respectively 0.8%, 0.8%, 0.85% different shrinking percentage, to have
The guarantee casting quality of effect；Specifically be that each casting structure size is different, shrinking percentage setting slightly has difference, control essence
Degree need to be less than 0.05%, i.e., design length shrinking percentage is 0.8% ± 0.05%, and shrinkage in width rate is 0.8% ± 0.05%, height
Shrinking percentage is 0.85% ± 0.05%.
The design of the drawing of rough casting is completed in conjunction with shrinking percentage and shell section product size, drawing of rough casting surplus design is that outer mold surface is unilateral remaining
Amount is greater than 6mm, and axial unilateral surplus is greater than 8mm；Axial design considerations of the unilateral surplus greater than 8mm be direction size first compared with
Greatly, it followed by needs to carry out benchmark adjustment in subsequent mechanical process, to guarantee big small end in metal cutting process
Face (it is in referring to figs. 2 and 3, pyramid type since the casting 1 is whole, is Specifically truncated cone-shaped, therefore rear end face 12 is large end face,
Front end face 13 is small end face) flatness, on the basis of the depth of parallelism, guarantee the concentricity and appearance profile degree of big small end face.Under
Face combines the specific application example, and entirety shell section casting and molding method tapered to above-mentioned large thin-wall aluminum alloy round is retouched in detail
It states:
S100, whole shell section casting and forming:
S101, ZL114A high strength alumin ium alloy are prepared: using essence Al ingot and Al-Si, Al-Cu, Mg and Ti- of refined aluminium founding
B intermediate alloy alloyage；Using Al-Ti-B intermediate alloy refining alloy tissue, while copper and mickel element is added, and aluminium is added
Strontium intermediate alloy improves morphology of eutectic silicon, optimized alloy constituent content；It is refined using high-purity argon gas, obtains the high-strength aluminium of ZL114A and close
Gold.In the configuration process of the present embodiment, smart Al ingot is melted first, by elements such as above-mentioned Si, Cu, Mg with intermediate alloy block or
In the form investment molten aluminum of element simple substance block, preparation obtains the ZL114A high strength alumin ium alloy.In other embodiments, can also first by
Smart Al ingot and copper billet melt, then the elements such as above-mentioned Si, Mg, Ni are put into the form of intermediate alloy block or element simple substance block and are melted
Melt in liquid.
The weight percent of the chemical component of ZL114A high strength alumin ium alloy are as follows: Si content is 6.5%~7.5%；Cu content
It is 1%~3%；Mg content is 0.45%~0.75%；Ti+Ni total content is 0.05%~0.1%；B content be 0.05%~
0.1%；Sr content is less than 0.01%；Total impurities≤0.75%, wherein major impurity Fe content < 0.1%；Surplus is Al, Al
90% or more total amount answer seizure ratio.In the present embodiment, the control of Si content limits in a standard, and about 7%；Mg is more than middle limit, about
It is 0.65%；Ti content is set as high limit, about 0.09%.
S102, production furan resin-sand entirety sand mold:
S1021, process inner mold mold and exterior mold based on default geometric dimension: the inner mold mold uses aluminium alloy mould
Tool, to guarantee the inner mold of product and avoid deformation caused by shrinking uneven, exterior mold uses wooden model, to reduce mold manufacture
Cost；
Due to being large thin-wall aluminum alloy cabin casting and forming mold, because the limitation of structure size can not use unitary mould
Structure and must be using assembled composable mold structure, therefore adopted between the assembling combination positioning method of mold, die assembly block
Connector, mold insert designs, mold manufacture, mold assembly etc. are most important, and the present embodiment uses following steps
Make inner mold mold and exterior mold:
It is primarily based on default geometric dimension processing inner mold mold block and exterior mold block, inner mold mold block and exterior mold block
Manufacture all use numerical control processing；The position between width, height, thickness and grid ribs to guarantee each grid ribs
Degree, the inner mold mold block (insert) for constituting the grid ribs position of inner mold mold are made of furan resin-sand, manufactured furans tree
Rouge sand inner mold mold block surface sprayed coating, to control deformation retract when solidification；
Inner mold mold block is located by connecting by using the mistake that 1 stub cooperates 2 or more auxiliary pins to be located by connecting
Using axial assembling combination as inner mold mold, such as+4 auxiliary pins of 1 stub, used stub use stainless steel pin shaft；It spells
Whole finishing is carried out again after dress combination, to guarantee the type face precision of inner mold mold；
Exterior mold block is located by connecting by using the mistake that 1 stub cooperates 2 or more auxiliary pins to be located by connecting
Using axial assembling combination as exterior mold, such as+4 auxiliary pins of 1 stub, used stub use stainless steel pin shaft；It spells
Whole finishing is carried out again after dress combination, to guarantee the type face precision of exterior mold.
S1022, founding make interior model sand mold and outer model sand mold:
Interior model sand mold is manufactured using founding based on inner mold mold, outer model sand mold is manufactured using founding based on exterior mold, outside
Furan resin-sand of the model sand mold using formwork thickness greater than 200mm or more is as formwork, quickly to absorb the heat in cooling procedure
Amount；
In the resin sand that the external coating of interior model sand mold is mixed by the scouring sand and PEPSET resin of 70~140 mesh,
Resin sand can mainly guarantee part the size of each part precision, and sand bond is good, indeformable, and cast(ing) surface can be made bright and clean, beautiful
It sees, and resin sand collapsibility is good, easy sand removal；
In order to improve the surface smoothness of casting and the surface strength of raising type core, type core is after molding, in furan after molding
The whose surfaces of furane resins sand entirety sand mold use quick drying paint brushing 2~3 times, fill mould surface gap, dry again later
Polishing, to guarantee the surface quality of casting；
S1023,3-D scanning detect interior model sand mold and outer model sand mold: before inside and outside model sand mold combination, need to distinguish internal sand
Type and outer model sand mold carry out 3-D scanning detection, and emphasis is that internal model sand mold carries out three dimensional detection, it is ensured that the shape of interior model sand mold
Profile tolerance and dimensional accuracy；
Outer model sand mold is detected using stock size, and examination criteria is to ensure to shrink in whole sand casting entirety shell section casting
In the case where, the machining allowance of whole shell section casting shape is meeting the tapered whole shell section profile tolerance of large thin-wall aluminum alloy round
Under the premise of it is small as far as possible, to reduce the subsequent whole shell section process-cycle；
The point cloud of interior model sand mold three-dimensional camera shooting scanning and interior model sand mold theory three-dimensional model are fitted comparison, fitting side
Formula uses best fit mode, and high point region red and yellow in the color point cloud atlas after the fitting of interior model sand mold is passed through craft
The mode of polishing or cutting removes, it is ensured that the region one of interior model sand mold profile tolerance and 95% or more area of theory three-dimensional model
It causes.
S1024, interior model sand mold and outer model sand mold and necessary casting supplementary structure are assembled, obtains furane resins
Sand entirety sand mold:
The combination of interior model sand mold and outer model sand mold is using traditional big plane+cross chute cooperation pin hole positioning assembly side
Formula, safe reliable, to improve casting ontology mechanical property, front and back end frame is all made of the chill that thickness is greater than 20mm.
The casting of S103, ZL114A high strength alumin ium alloy: using rising pouring clearance type casting system, and casting mode is anti-using bottom filling
Gravity squeezes casting；
Casting system design and the core of analog simulation are that stamp when effectively guaranteeing casting is completely reliable, by dividing
Not Cai Yong three kinds of PROCAST/HUSTCAE/ANYCASTING etc. whole sand casting simulation softwards carry out sunykatuib analyses, it is same to pour
Preferentially it has been determined that the casting system, i.e. the present embodiment use rising pouring clearance type and pour after the three kinds of analog result synthetical comparison and assessment of casting system
Casting system has been evaded the crackle being likely to occur when whole sand casting, Susong, shrinkage cavity entirety sand casting defect, has been evaded simultaneously
Rigidity is too strong after casting system solidification or rigidity is excessively weak and leads to successive castings solution treated, the complete timeliness of quenching, casting
The large deformation risk in the stages such as system removal.Need in real time carry out the imperfect place of the drawing of rough casting perfect when casting system designs, than
Local increase is carried out as rigidity is insufficient or is unfavorable for the region of stamp, is removed again after casting.
The casting of anti-gravity bottom filling has been respectively adopted in casting mode and anti-gravity bottom filling squeezes casting two ways, from whole
From the point of view of the risk and result of body sand casting deformation, anti-gravity bottom filling squeezes casting and casts better than anti-gravity bottom filling, punching
Type is more complete, while the defects of evaded many loose shrinkage cavities with pressure casting.
Bottom filling anti-gravity squeezes the concrete operations content of casting are as follows:
Ensure that the temperature in casting furnace is greater than 40 DEG C before casting, carries out casting furnace preheating and drying, and control in casting furnace
Humidity is less than 80%；The temperature of aluminum alloy melt is controlled when casting at 680 DEG C~720 DEG C, the present embodiment uses 695 DEG C~715 DEG C,
Winter and the control of summer temp difference are at 10 DEG C or so；The molten aluminum of casting is 1.5 times or more of casting+casting system total weight, this
The crucible capacity minimum that serial shell section uses must not be lower than 1000 kilograms, and squeeze pressure is greater than 0.1Mpa, to ensure the pressure of stamp
Power and speed；The stamp time is 20s~40s, and the present embodiment uses 30s, and dwell pressure is 0.1MPa~0.12MPa, when pressure maintaining
Between be 250s~350s, the present embodiment use 300s；After casting after furnace temperature drops to room temperature, blow-on after standing 4 hours is obtained
Whole shell section casting.
S104, removal casting system: the removal of casting system is carried out after Scavenger resin sand；
The step can be completed using traditional hand cut or machine cuts: when using hand cut, it is to be ensured that cut
Position is cut slightly far from casting ontology, closely causes very much damage to cast(ing) surface and loss of rigidity excessive to avoid cutting position；It adopts
When being removed with machine cut mode subsequent manual grinding, rest and reorganization process are reduced while making rational planning for cutting path.
S105, three-dimensional camera shooting scanning is carried out to whole shell section casting:
It removes in casting and three-dimensional camera shooting scanning is carried out to casting outer mold surface after the running channel of outer mold surface, by the point Yun Hezhu of scanning
Part cube theory external form compares, and analyzes its external form profile tolerance；Because most of running channel is located in inner mold chamber in the present embodiment
Face and 3-D scanning can not carry out, therefore to outer mold surface using three-dimensional digital camera-shooting scanning detection compare and analyze；Inner mold
Face carries out 3-D scanning using flexible joint coordinate measuring machine, thus judge whether the inner mold chamber profile tolerance of casting meets the requirements,
Whether toothpick machining allowance meets the requirements, and the shrinking percentage of casting controls whether the target for meeting design.The data can be used as subsequent
Produce the foundation of surplus and shrinking percentage design optimization in batches.
S200, whole shell section heat treatment:
S201, heat treatment tooling assembly:
Same material is selected in conjunction with the rigidity of shell section according to ZL114A high-strength aluminum alloy material thermal expansion coefficient, intensity
Material type selecting of the aluminium alloy as heat treatment tooling, and all connecting pins are all made of aluminum alloy materials；Rigidity aspect focuses on
The rigidity of heat treatment tooling is slightly above the rigidity of Al alloy shell section ontology, or by closing connection design, by heat treatment tooling
A closed entirety is formed after connecting with shell section, to control the deformation of shell section heat treatment.Rigidity is carried out by ANSYS software
Analysis and solution is calculated, while calculating its temperature Thermal deformation and being in elastic range.
Heat treatment positioning tool guarantees that connection is reliable first, secondary combination temperature thermal deformation trend, guarantees the heating of shell section
The freedom degree of thermal expansion in the process, therefore screw-down torque appropriate is taken in the assembly of mating surface when heat treatment tooling manufacture,
Torque is excessive too small unfavorable.
After S202, shell section+tool locating assembly, the detection of first time 3-D scanning is carried out to whole shell section casting, is recorded whole
The external form surface profile of body shell section casting, and the benchmark as deformation after unloading detection.
S203, solution treatment and T6 quenching are carried out to whole shell section casting；
There are solid solution temperature, solid solution to the influence factor of alloy property when Al-Si system ZL114 high strength alumin ium alloy is heat-treated
Handle time, hardening media temperature, aging temp, aging time etc.；It, usually will solid solution temperature in order to obtain maximum solid solution effect
Degree is raised near eutectic temperature as far as possible, but burning cannot occur；Technological parameter appropriate is selected, obtains alloy property effectively
It improves, the specific parameter that is dissolved is:
Whole shell section casting is warming up to 520 DEG C first, keeps the temperature 2h at a temperature of 520 DEG C, then by whole shell section casting liter
Temperature is come out of the stove after keeping the temperature 8h at a temperature of 538 DEG C to 538 DEG C；
It quenches in dedicated aluminum alloy quenching liquid after solution treatment, is turned whole shell section casting with the speed less than 20s
Move into liquid, the temperature of aluminum alloy quenching liquid is not less than 70 DEG C, whole shell section casting using up and down it is vertical enter aqueous, prevent because of quenching
Cause casting deformation, heat treating castings rationally design disposing way, enter water direction and frock clamp is extremely important.
S204, second of 3-D scanning detection is carried out to whole shell section casting, on the basis of whole shell section casting inner mold face,
It is detected using best fit mode, will test result and be compared first with the model of first time 3-D scanning detection, from
And judge that solution treatment and T6 quenching technical, running channel remove and whether heat treatment tooling design is reasonable, it is synchronous to judge whole shell
Whether deform after section casting and heat treatment tooling positioning assembly.
S205, heat treatment tooling is removed, the detection of third time 3-D scanning then is carried out to whole shell section casting, it will third time
The scanning result that the scanning result of 3-D scanning detection is detected with first time 3-D scanning compares, to detect whole shell
The deflection of section heat treating castings；The theory of scanning result and whole shell section casting that further third time 3-D scanning is detected
Target value compares, the judgment basis checked and accepted as final casting deflection and geometric dimension.It is preferable in each Absent measures
In the case of, it can effectively carry out avoiding heat treatment bring risk of distortion while shell section stress equalizing, according to detection knot
Fruit, at this time appearance profile degree deformation need to control within 0.5mm.
After S206, removal heat treatment tooling, ageing treatment is carried out to whole shell section casting:
Artificial aging processing is carried out to whole shell section casting in desk-top drying box, timeliness parameter is by whole shell section casting
165 DEG C are warming up to, comes out of the stove after heat preservation 8h and is air-cooled to room temperature.
S207, the 4th 3-D scanning detection, the scanning that the 4th 3-D scanning is detected are carried out to whole shell section casting
As a result the scanning result with the detection of third time 3-D scanning compares, to detect the change of whole shell section cast part age processing
Shape amount.Artificial aging can effectively carry out the stress equalizing of shell section and the elimination of casting residual stress, to reduce because of remnants
Following process deflection caused by stress and Stress non-homogeneity, according to testing result, appearance profile degree deformation at this time is on the left side 0.2mm
It is right.
S208, X-ray and fluoroscopy are carried out to whole shell section casting, judge in whole shell section casting with the presence or absence of Susong,
Shrinkage cavity, crackle defect, and whether carry out repairing measures according to defect dipoles, repairing measures include: the apparent micro-crack of casting
It is eliminated by polishing, apparently open shrinkage cavity can be eliminated casting by repair welding, or carry out the diffusion that stop hole evades crackle.
S300, whole shell section processing: roughing and finishing are carried out to whole shell section casting, obtain large thin-wall aluminium alloy
Pyramid type entirety shell section；
Reference measurement before S301, whole shell section Mechanical processing of casting:
S3011, levelling whole shell section casting housing rear end face 12, are processed light-exposed；S3012, then with whole shell section casting
On the basis of inner mold face, crosses on the cross rectangle technique boss of the back-end box of whole shell section casting, determine center；It is S3013, thick
Process cross rectangle technique boss.
S302, the 3-D scanning of whole shell section casting and detection:
S3021, detection coordinate system O1xyz, scanning are determined with machined rear end face 12 and cross rectangle technique boss
Whole shell section casting shell inner mold face and outer mold surface；S3022, on the basis of the whole shell section casting inner mold face, scanning is obtained
Scan model and theoretical model carry out best fit, analyze whole shell section casting inner mold surface profile, external form surface profile and
End face plane degree；S3023, the machining allowance distribution situation for detecting whole shell section casting；S3024, after best fit, determine after
End face 12, cross rectangle technique boss and the positional relationship for detecting coordinate system O1xyz.
S303, adaptive machining roughing standard:
S3031, by rear end face 12 upward, centering rear end face 12 and cross rectangle technique boss, determine detection coordinate system
O1xyz；S3032, coordinate system biasing is carried out with the rapport that best fit determines, determines actual processing coordinate system O2xyz；
S3033, Milling Process rear end face 12, made allowance 2mm, and coordinate the ring-like grid ribs center of whole shell section cast-internal away from whole shell
The distance of section casting front end face 13 and rear end face 12；S3034, Milling Process entirety shell section casting rear end inner mold profile, single side stay
Surplus 2mm；(3-3-5) processes the dowel hole on rear end face 12, made allowance 2mm.
S304, according to roughing standard roughing shell shape；
S3041, it is positioned, the front end face 13 of Milling Process entirety shell section casting, is stayed remaining with rear end face 12 and dowel hole
Measure 2mm；S3042, milling entirety shell section casting shell shape, unilateral made allowance are not less than 1.5mm；S3043, roughing entirety shell
All shape windows and rudderpost hole characteristic of section casting, unilateral made allowance are not less than 2mm.
S305, size detection and first time 3-D scanning:
S3051, the size that whole shell section casting after roughing is detected using large-scale vernier caliper and template；S3052, use
3 D detection method detects whole shell section casting shell inner mold surface profile, outer on the basis of rear end face 12 and dowel hole
Machined surface profile degree, end face plane degree geometric tolerance.
S306, heat treatment artificial aging destressing:
S3061, heating furnace is warming up to setting process parameters range, whole shell section casting is placed into bottom plate tooling is vertical
Furnace；S3062, artificial aging is carried out, continues 8h using 150 DEG C of furnace temperature duration 4h, or using 120 DEG C of furnace temperature；S3063,
It is air-cooled after whole shell section casting furnace cooling.
S307, second of 3-D scanning geometry detection:
S3071, whole shell section casting is placed on workbench, centering rear end face 12 and dowel hole, is established three-dimensional
Scan coordinate system O3xyz；S3072, inner mold face 3-D scanning is carried out to whole shell section casting and carries out points cloud processing；S3073, general
Point cloud is compared with theoretical model, analyzes whole shell section casting deformation dimensional conditions distribution, and carry out deformation tendency analysis；
S3074, deformation of the whole shell section casting before and after artificial aging is compared, foundation batch deformation judges whether to use
Heat treatment tooling carries out artificial aging deformation constraint, and judgment basis is that inner mold surface profile deformation deviation is less than 0.3mm；S3075,
According to batch deformation, consider whether to carry out artificial aging deformation constraint using heat treatment tooling.
S308, coordinated to process smart benchmark according to the uniformity requirement of inner mold surface profile and wall thickness:
S3081, the uniformity that inner mold face surplus is judged according to each face surplus in whole shell section casting inner mold face are with inner mold face
The scan model of second of 3-D scanning is fitted by benchmark again with theoretical model, determines the amount of bias of coordinate system after fitting；
S3082, coordinate system biasing is carried out with amount of bias, determines finishing coordinate system O4xyz, processes rear end face 12, remove surplus, processing
To design size；S3083, processing rear end inner mold profile to design size；On S3084, processing dowel hole and rear end face 12
Connecting hole is to design size；
S309, shell outer mold surface and interior surface-type feature are finished according to smart benchmark:
S3091, with rear end face 12 and dowel hole it is smart benchmark, finishes the end face on front end face 13 and front end face 13
Hole is to design size；S3092, whole shell section casting front end inner mold profile and inner mold characteristic window are finished to design size；
S3093, the pin hole on finishing front end face 13 and connecting hole are to design size；Under S3094, finishing outer mold surface and shape
It falls into；S3095, rudderpost, high-precision porous and the window of whole shell section casting are finished to design size；
S310, finishing back casing is detected:
S3101, the linear dimension that finishing back casing is detected using conventional method；S3102, with rear end face 12 and positioning pin
Kong Weijing benchmark detects finishing back casing inner mold surface profile and external form surface profile using 3-D scanning detection method；
S3103, with rear end face 12 and dowel hole be smart benchmark, using three-dimensional coordinates measurement rudderpost, high-precision porous dimensional tolerance and
Geometric tolerance.
The tapered whole shell section of the large thin-wall aluminum alloy round cast through the foregoing embodiment, sand-cast chemical component are answered
Meet the regulation of QJ3185-2003；Meet I class castings desire of GB/T9438-1999 " aluminium alloy castings "；Surface quality of continuous castings,
Internal soundness requires to execute by GB/T9438-1999；T6 state is heat-treated to using GJB1965-1993, shell section front and back end frame and
Each position of covering body sampling is no less than at 3, and mechanics Properties Tensile/yield strength index is not less than under room temperature and the condition of high temperature
The regulation of HB962-2001.
Through detecting, the properties of the tapered whole shell section of the large thin-wall aluminum alloy round are as follows:
(1) shell section foundry engieering index:
(a) cabin residual stress removal degree is no less than 70%, and hydrogen content is not more than 0.015% after material heat treatment；(b)
Shell section casts machining allowance and is less than 8mm, target control 5mm；(c) casting inner mold profile tolerance is guaranteed by casting, and is not less than
0.5mm；(d) weight allowance of casting meets ± 4%；(e) product casting qualification rate is no less than 90%.
(2) casting physical and mechanical properties:
Mechanical castings index request is as shown in table 1.The mechanical property that sample or attached casting sample are cut on casting,
Ask room temperature, 150 DEG C, the mechanical property at 200 DEG C.Wherein sand casting room temperature elongation percentage requires to be greater than 6%, melts die cast room temperature
Elongation percentage is greater than 4.5%.
1 mechanical castings index of table
(3) cabin Internal Quality of Cast:
The pin hole of shell intersegmental part and loose requirement are as shown in table 2.Shell intersegmental part allows to have following defect: allowing shell intersegmental part
There are single stomata and slag inclusion, diameter or full-size are not greater than 3mm, the quantity on any 10cm × 10cm unit area
3 must not be more than, back gauge cannot be less than 30mm；Shell intersegmental part is allowed to have groups of stomata and slag inclusion, diameter or full-size
It is not greater than 1.5mm, the quantity on the unit area of 3cm × 3cm must not be more than 3, and the distance between group and group must not be small
In 50mm；The edge of drawbacks described above cannot be less than 30mm far from the distance at shell section edge, bore edges, boss edge.Shell section 100% into
The defects of row X-ray procedure, inside is not allow for crackle, cold shut, does not merge.
2 internal flaw of table allows rank
(4) cabin geometric accuracy index
(a) 1000 ± 0.4mm of product height dimension, shell section outside diameter 973.5 ± 0.2mm of Φ, end diameter Φ 844.2
±0.2mm；(b) big small end and theoretical centerline axis concentricity≤0.3mm, outer surface profile degree are not more than 0.4mm, external surface pair
Title degree is not more than 0.3mm；(c) shell section wall thickness control is 3 ± 0.5mm, is allowed within the thickness 1mm of casting part, allow to polish interior table
Face；(d) four mounting hole dimension precision requirements are higher, and wherein diameter of bore isSame assembly
Face concentricity is 0.02, verticality 0.1；(e) after being heat-treated timeliness during Mechanical processing of casting, machined surface profile degree and symmetry
It reduces no more than 0.20mm.
Through the foregoing embodiment, the invention has the advantages that advantage:
1) the tapered whole shell section casting and molding method of large thin-wall aluminum alloy round provided by the invention, for the environment of product
Operating condition and design feature demand systematically analyze the tapered whole shell section sand casting of large thin-wall aluminum alloy round, heat treatment, numerical control
The deformation characteristics of each technology major links such as processing；It is detected by whole sand casting molding simulation simulation optimization, 3-D scanning
Technology, casting cabin machining allowance distribution and machining benchmark Feature Conversion, the reinforcing of heat treatment tooling rigidity, heat-treatment quenching
With the Deformation controls technology method such as artificial aging, it is effectively controlled each work of the tapered whole shell section of large thin-wall aluminum alloy round
The deformation of skill link ensure that aerodynamic configuration, the shell section metal bearing layer evenness of wall thickness of product, shell section overall weight mass center etc.
Key technical index；It has effectively captured in the tapered whole shell section hot investment casting molding of large thin-wall aluminum alloy round and process
Serial key technology, ensure that the overall quality of the tapered whole shell section precise forming processing and manufacturing of large thin-wall aluminum alloy round,
The manufacturing cycle is shortened while reducing manufacturing cost.
2) the tapered whole shell section casting and molding method of large thin-wall aluminum alloy round provided by the invention, using high purity alloys ingot
Alloyage, optimized alloy ingredient using Al-Ti-B intermediate alloy refining alloy tissue, while adding a small amount of copper and mickel member
Element, and improve morphology of eutectic silicon with aluminium-strontium master alloy, using high-purity argon gas refined alloy.Using rafifinal and high-purity intermediate conjunction
Gold prepares ZL114A high strength alumin ium alloy, and optimized alloy constituent content.Using smart A1 ingot and Al-Si, Al-Cu of refined aluminium founding,
Mg, Ti-B intermediate alloy alloyage exist major impurity Fe control of the Control of Impurities in alloy in bottom line, alloy
0.1% hereinafter, make alloy " purifying "；It is realized secondly by control alloying component and impurity content in control alloy structure
Phase composition: Si, Mg be the main intensified element of ZL114A high strength alumin ium alloy, formed Mg-Si phase precipitation strength, when Si content is high,
Primary silicon will affect the intensity and elongation of alloy, therefore the control of Si content limits in a standard；The content of Mg should sufficiently with Si shape
At enough Mg-Si phases, ingredient should be more than middle limit；Ti within the scope of standard analysis, can set Ti to only mutually there is refining effect
For high limit.Using Al-Ti-B intermediate alloy come the tissue of refining alloy, the intensity of alloy is can be improved in grain refining alloy tissue
And elongation.
3) the tapered whole shell section casting and molding method of large thin-wall aluminum alloy round provided by the invention, the large thin-wall aluminium close
Golden pyramid type entirety shell section uses ZL114A high strength alumin ium alloy, and compared to national standard ZL114A, the high-strength aluminium of the ZL114A of the application is closed
Cu element is increased in gold, to improve the intensity and extensibility of the alloy, due to the addition of Cu element, Cu is in configuration ZL114A
It is easily segregated when high strength alumin ium alloy, the application passes through the addition of Sr element, can effectively inhibit the segregation of Cu；Nickel and aluminium titanium boron
Intermediate alloy addition can refining alloy tissue.
4) there is solution treatment temperature to the influence factor of alloy property when the heat treatment of research discovery Al-Si system cast aluminium alloy gold
Degree, solution treatment time, hardening media temperature, aging temp, aging time etc.；Large thin-wall aluminum alloy round provided by the invention
Tapered entirety shell section casting and molding method, shell section can be protected effectively after T6 heat treatment and artificial aging in aspect of performance
The compactness for demonstrate,proving cast-internal tissue, solid solubility temperature is raised near eutectic temperature as far as possible, but burning does not occur, and selection is appropriate
Technological parameter, so that alloy property is effectively improved, obtain maximum solid solution effect.
5) research discovery cooling velocity has larger impact for cast properties；Large thin-wall aluminum alloy round provided by the invention
Tapered entirety shell section casting and molding method passes through reasonable smelting process formula, the design of reasonable casting system, reasonable casting
Technological parameter and heat treatment process parameter improve, and the room temperature and mechanical behavior under high temperature that can effectively improve casting refer to elongation percentage
Mark.
Although the preferred embodiment of the application has been described, but one of ordinary skilled in the art once knows substantially
Creative concept, then additional changes and modifications may be made to these embodiments.It is wrapped so the following claims are intended to be interpreted as
It includes preferred embodiment and falls into all change and modification of the application range.
Obviously, those skilled in the art can carry out various modification and variations without departing from the essence of the application to the application
Mind and range.In this way, if these modifications and variations of the application belong to the range of the claim of this application and its equivalent technologies
Within, then the application is also intended to include these modifications and variations.
Claims (10)
1. a kind of tapered whole shell section casting and molding method of large thin-wall aluminum alloy round, which comprises the steps of:
(1) whole shell section casting and forming: using rising pouring clearance type casting system, whole in furan resin-sand according to the pre-designed drawing of rough casting
Aluminium alloy bottom filling anti-gravity is carried out in body sand mold squeezes casting；
Ensure that the temperature in casting furnace is greater than 40 DEG C before casting, carries out the casting furnace preheating and drying, and control the casting
Humidity is less than 80% in furnace；The temperature of the aluminum alloy melt is controlled when casting at 680 DEG C~720 DEG C, squeeze pressure is greater than
0.1Mpa, stamp time are 20s~40s, and dwell pressure is 0.1MPa~0.12MPa, and the dwell time is 250s~350s；Casting
Afterwards after furnace temperature drops to room temperature, blow-on after standing 4 hours obtains the whole shell section casting；
(2) solution treatment, T6 quenching and ageing treatment whole shell section heat treatment: are carried out to the whole shell section casting；
(3) whole shell section processing: roughing and finishing are carried out to the whole shell section casting, the large thin-wall aluminium is obtained and closes
Golden pyramid type entirety shell section.
2. the tapered whole shell section casting and molding method of large thin-wall aluminum alloy round as described in claim 1, it is characterised in that: step
Suddenly in (1), the aluminium alloy is ZL114A high strength alumin ium alloy, and the ZL114A high strength alumin ium alloy is prepared with the following method:
Using smart Al ingot and Al-Si, Al-Cu, Mg and Ti-B intermediate alloy alloyage of refined aluminium founding；Nickel element is added,
And aluminium-strontium master alloy improvement morphology of eutectic silicon, optimized alloy constituent content is added；It is refined, is obtained described using high-purity argon gas
ZL114A high strength alumin ium alloy；
The weight percent of the chemical component of the ZL114A high strength alumin ium alloy are as follows: Si content is 6.5%~7.5%；Cu content
It is 1%~3%；Mg content is 0.45%~0.75%；Ti+Ni total content is 0.05%~0.1%；B content be 0.05%~
0.1%；Sr content is less than 0.01%；Total impurities≤0.75%, wherein major impurity Fe content < 0.1%；Surplus is Al.
3. the tapered whole shell section casting and molding method of large thin-wall aluminum alloy round as claimed in claim 1 or 2, feature exist
In: in step (1), the pre-designed drawing of rough casting specifically: design length shrinking percentage is 0.8% ± 0.05%, shrinkage in width rate
It is 0.8% ± 0.05%, high shrinkage rate is 0.85% ± 0.05%；The unilateral surplus of designing cast outer mold surface is greater than 6mm, casting
Axial unilateral surplus is greater than 8mm.
4. the tapered whole shell section casting and molding method of large thin-wall aluminum alloy round as described in claim 1, it is characterised in that: step
Suddenly in (1), the furan resin-sand entirety sand mold makes with the following method:
Inner mold mold and exterior mold are processed based on default geometric dimension；
Interior model sand mold is manufactured using founding based on inner mold mold, outer model sand mold is manufactured using founding based on exterior mold, it is described outer
The formwork thickness of model sand mold is greater than 200mm；
The interior model sand mold and the outer model sand mold are assembled, the furan resin-sand entirety sand mold is obtained.
5. the tapered whole shell section casting and molding method of large thin-wall aluminum alloy round as claimed in claim 4, it is characterised in that: institute
It states based on default geometric dimension processing inner mold mold and exterior mold, comprising:
Inner mold mold block and exterior mold block are processed based on default geometric dimension；
The inner mold mold block was passed through and was located by connecting with axial assembling combination for the inner mold mold, by the exterior mold
Block, which passed through, to be located by connecting with axial assembling combination as the exterior mold；The mistake is located by connecting specially using 1 stub
Cooperation 2 or more auxiliary pin is located by connecting；
The inner mold mold block for constituting the grid ribs position of the inner mold mold is made of furan resin-sand, manufactured described
Furan resin-sand inner mold mold block surface sprayed coating.
6. the tapered whole shell section casting and molding method of large thin-wall aluminum alloy round as claimed in claim 4, it is characterised in that: step
Suddenly described that interior model sand mold is manufactured using founding based on inner mold mold in (1), outer model sand mold is manufactured using founding based on exterior mold
Afterwards, the furan resin-sand entirety sand mold production method further include:
In the resin sand that the external coating of the interior model sand mold is mixed by the scouring sand and PEPSET resin of 70~140 mesh；
It uses quick drying paint brushing 2~3 times after molding in the whose surfaces of the furan resin-sand entirety sand mold, is carried out after drying
Polishing.
7. the tapered whole shell section casting and molding method of large thin-wall aluminum alloy round as described in claim 4 or 6, feature exist
In: in step (1), it is described the interior model sand mold and the outer model sand mold are assembled before, the furan resin-sand unit sand
Type production method further include:
3-D scanning detection is carried out to the furan resin-sand entirety sand mold: respectively to the interior model sand mold and the outer model sand mold
3-D scanning detection is carried out, the outer model sand mold is detected using stock size, and examination criteria is whole in whole sand casting to ensure
In the case that body shell section casting is shunk, the machining allowance of the entirety shell section casting shape is meeting the large thin-wall aluminium alloy
It is small as far as possible under the premise of pyramid type entirety shell section profile tolerance, to reduce the subsequent whole shell section process-cycle；
The point cloud of the interior model sand mold three-dimensional camera shooting scanning and the interior model sand mold theory three-dimensional model are fitted comparison, intended
Conjunction mode uses best fit mode, by red and yellow high point region in the color point cloud atlas after the interior model sand mold fitting
It is removed by way of manual grinding or cutting, it is ensured that the interior model sand mold profile tolerance and theory three-dimensional model 95% are with above
Long-pending region is consistent.
8. the tapered whole shell section casting and molding method of large thin-wall aluminum alloy round as described in claim 1, it is characterised in that: step
It is suddenly described that solution treatment, T6 quenching and ageing treatment are carried out to the whole shell section casting in (2), comprising:
The whole shell section casting and heat treatment tooling are carried out positioning assembly by (2-1), the material of the heat treatment tooling and
The material of connecting pin used in positioning assembly is the aluminium alloy with the whole shell section casting same material；
(2-2) carries out the detection of first time 3-D scanning to the whole shell section casting, records the external form of the whole shell section casting
Surface profile, and the benchmark as deformation after unloading detection；
(2-3) carries out solution treatment to the whole shell section casting and T6 is quenched；
(2-4) carries out second of 3-D scanning detection to the whole shell section casting, is with the whole shell section casting inner mold face
Benchmark is detected using best fit mode, will test result first with the first time 3-D scanning detection model into
Row compares, to judge whether the solution treatment and T6 quenching technical and heat treatment tooling design are reasonable, synchronize and sentence
Break the whole shell section casting and heat treatment tooling positioning assemble after whether deform；
(2-5) removes the heat treatment tooling, then the detection of third time 3-D scanning is carried out to the whole shell section casting, by institute
The scanning result that the scanning result that third time 3-D scanning detects is detected with the first time 3-D scanning is stated to compare, thus
Detect the deflection of the whole shell section heat treating castings；The scanning result that further the third time 3-D scanning is detected
It is compared with the theoretical target values of the whole shell section casting, the judgement checked and accepted as final casting deflection and geometric dimension
Foundation；
(2-6) carries out ageing treatment to the whole shell section casting；
(2-7) carries out the 4th 3-D scanning detection to the whole shell section casting, by the 4th 3-D scanning detection
The scanning result that scanning result is detected with the third time 3-D scanning compares, to detect the whole shell section casting
The deflection of ageing treatment；
(2-8) carries out X-ray and fluoroscopy to the whole shell section casting, judges in the whole shell section casting with the presence or absence of place
Pine, shrinkage cavity, crackle defect, and whether carry out repairing measures according to the defect dipoles, the repairing measures include: casting table
The micro-crack of sight is eliminated by polishing, and apparently open shrinkage cavity can be eliminated casting by repair welding, or is carried out stop hole and evaded
The diffusion of crackle.
9. the tapered whole shell section casting and molding method of large thin-wall aluminum alloy round as claimed in claim 1 or 8, feature exist
In: in step (2), the solution treatment includes:
The whole shell section casting is warming up to 520 DEG C first, keeps the temperature 2h at a temperature of 520 DEG C, then by the whole shell Duan Zhu
Part is warming up to 538 DEG C, comes out of the stove after keeping the temperature 8h at a temperature of 538 DEG C；
The T6 is quenched
It is quenched in aluminum alloy quenching liquid, the whole shell section casting is transferred to by liquid, the entirety shell with the speed less than 20s
Section casting using up and down it is vertical enter aqueous, the temperature of the aluminum alloy quenching liquid is not less than 70 DEG C；
The ageing treatment includes:
Artificial aging processing is carried out to the whole shell section casting in desk-top drying box, the whole shell section casting is warming up to
It 165 DEG C, comes out of the stove after keeping the temperature 8h and is air-cooled to room temperature.
10. the tapered whole shell section casting and molding method of large thin-wall aluminum alloy round as described in claim 1, it is characterised in that:
It is described that roughing and finishing are carried out to the whole shell section casting in step (3), obtain the large thin-wall aluminium alloy circular cone
Type entirety shell section, comprising:
Reference measurement before (3-1) entirety shell section Mechanical processing of casting:
The levelling described whole shell section casting housing rear end face (3-1-1), is processed light-exposed；(3-1-2) is then with the whole shell section
On the basis of casting inner mold face, crosses on the cross rectangle technique boss of the back-end box of the whole shell section casting, determine center；
Cross rectangle technique boss described in (3-1-3) roughing；
The 3-D scanning of (3-2) entirety shell section casting and detection:
(3-2-1) determines detection coordinate system O1xyz with the machined rear end face and the cross rectangle technique boss, sweeps
Retouch the whole shell section casting shell inner mold face and outer mold surface；(3-2-2), will on the basis of the whole shell section casting inner mold face
It scans obtained scan model and theoretical model carries out best fit, analyze the whole shell section casting inner mold surface profile, outer
Machined surface profile degree and end face plane degree；The machining allowance distribution situation of (3-2-3) detection whole shell section casting；(3-2-
4) after the best fit, the rear end face, the cross rectangle technique boss and the detection coordinate system O1xyz are determined
Positional relationship；
(3-3) adaptive machining roughing standard:
(3-3-1) is face-up by the rear end, rear end face described in centering and the cross rectangle technique boss, determines that detection is sat
Mark system O1xyz；(3-3-2) carries out coordinate system biasing with the rapport that the best fit determines, determines actual processing coordinate
It is O2xyz；Rear end face described in (3-3-3) Milling Process, made allowance 2mm, and coordinate the ring-like net of the whole shell section cast-internal
Distance of the lattice muscle center away from the whole shell section casting front end face and rear end face；Entirety shell Duan Zhu described in (3-3-4) Milling Process
Part rear end inner mold profile, single side made allowance 2mm；(3-3-5) processes the dowel hole on the rear end face, made allowance 2mm；
(3-4) is according to roughing standard roughing shell shape；
(3-4-1) is positioned with the rear end face and the dowel hole, the front end face of entirety shell section casting described in Milling Process,
Made allowance 2mm；Entirety shell section casting shell shape described in (3-4-2) milling, unilateral made allowance are not less than 1.5mm；(3-4-3) is thick
All shape windows and rudderpost hole characteristic of the whole shell section casting are processed, unilateral made allowance is not less than 2mm；
(3-5) size detection and first time 3-D scanning:
(3-5-1) detects the size of the whole shell section casting after roughing using large-scale vernier caliper and template；(3-5-2) is adopted
It is detected in the whole shell section casting shell on the basis of the rear end face and the dowel hole with 3 D detection method
Machined surface profile degree, external form surface profile, end face plane degree geometric tolerance；
(3-6) is heat-treated artificial aging destressing:
Heating furnace is warming up to setting process parameters range by (3-6-1), and the entirety shell section casting is with the vertical placement of bottom plate tooling
Enter furnace；(3-6-2) carries out artificial aging, continues 8h using 150 DEG C of furnace temperature duration 4h, or using 120 DEG C of furnace temperature；(3-
It is air-cooled 6-3) after the whole shell section casting furnace cooling；
(3-7) second of 3-D scanning geometry detection:
The whole shell section casting is placed on workbench by (3-7-1), and rear end face described in centering and the dowel hole are built
Vertical 3-D scanning coordinate system O3xyz；(3-7-2) carries out inner mold face 3-D scanning to the whole shell section casting and carries out at a cloud
Reason；(3-7-3) compares a cloud and the theoretical model, analyzes the whole shell section casting deformation dimensional conditions distribution,
And carry out deformation tendency analysis；Deformation of (3-7-4) comparison whole shell section casting before and after artificial aging, foundation batch
Deformation is measured, judges whether to carry out artificial aging deformation constraint using heat treatment tooling, judgment basis is inner mold surface profile
It deforms deviation and is less than 0.3mm；
(3-8) coordinates to process smart benchmark according to the uniformity requirement of inner mold surface profile and wall thickness:
(3-8-1) judges the uniformity of inner mold face surplus according to each face surplus in the whole shell section casting inner mold face, with described interior
On the basis of type face the scan model of second of 3-D scanning is fitted again with the theoretical model, determines coordinate after fitting
The amount of bias of system；(3-8-2) carries out coordinate system biasing with the amount of bias, finishing coordinate system O4xyz is determined, after processing is described
End face removes surplus, is worked into design size；(3-8-3) processes the rear end inner mold profile to design size；(3-8-4) adds
Connecting hole on dowel hole described in work and the rear end face is to design size；
(3-9) finishes shell outer mold surface and interior surface-type feature according to smart benchmark:
(3-9-1) is smart benchmark with the rear end face and the dowel hole, finishes the front end face and the front end face
On end-face hole to design size；(3-9-2) finishing whole shell section casting front end inner mold profile and inner mold Window
Mouthful to design size；(3-9-3) finishes pin hole on the front end face and connecting hole to design size；(3-9-4) finishing
Outer mold surface and shape are sunk；Rudderpost, high-precision porous and the window of (3-9-5) finishing whole shell section casting are to setting
Count size；
(3-10) detects finishing back casing:
(3-10-1) finishes the linear dimension of back casing using conventional method detection；(3-10-2) is with the rear end face and described
Dowel hole is smart benchmark, detects finishing back casing inner mold surface profile and external form facial contour using 3-D scanning detection method
Degree；(3-10-3) is smart benchmark with the rear end face and the dowel hole, using rudderpost described in three-dimensional coordinates measurement, described high-precision
Spend the dimensional tolerance and geometric tolerance of hole system.
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| CN114229044A (en) * | 2021-11-18 | 2022-03-25 | 北京卫星制造厂有限公司 | Method for preparing heat-proof suit of revolving body |
| CN114229044B (en) * | 2021-11-18 | 2023-07-25 | 北京卫星制造厂有限公司 | Preparation method of revolving body heat-proof suit |
| CN114749609A (en) * | 2022-04-22 | 2022-07-15 | 湖州市泷山机械有限公司 | Oil press piston casting process and production equipment |
| CN114643337A (en) * | 2022-04-28 | 2022-06-21 | 赛普工业研究院(安阳)有限公司 | Preparation method of barrel-shaped ZL208 alloy |
| CN114643337B (en) * | 2022-04-28 | 2023-10-27 | 赛普工业研究院(安阳)有限公司 | Preparation method of barrel-type ZL208 alloy |
| CN115837456A (en) * | 2022-12-02 | 2023-03-24 | 中科力祥科技股份有限公司 | Thin-wall revolving body part casting device and method based on aluminum alloy material |
| CN118237540A (en) * | 2024-05-30 | 2024-06-25 | 青州市铸威新材料科技有限公司 | Precoated sand shell for casting gearbox shell |
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