CN117900423A - Wheel antigravity casting method - Google Patents
Wheel antigravity casting method Download PDFInfo
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- CN117900423A CN117900423A CN202410083851.0A CN202410083851A CN117900423A CN 117900423 A CN117900423 A CN 117900423A CN 202410083851 A CN202410083851 A CN 202410083851A CN 117900423 A CN117900423 A CN 117900423A
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- 238000005266 casting Methods 0.000 title claims abstract description 48
- 238000000034 method Methods 0.000 title claims abstract description 47
- 238000001816 cooling Methods 0.000 claims abstract description 139
- 239000007788 liquid Substances 0.000 claims abstract description 56
- 238000000465 moulding Methods 0.000 claims abstract description 37
- 230000005484 gravity Effects 0.000 claims abstract description 26
- 230000008569 process Effects 0.000 claims abstract description 23
- 238000002347 injection Methods 0.000 claims abstract description 12
- 239000007924 injection Substances 0.000 claims abstract description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 98
- 229910052751 metal Inorganic materials 0.000 claims description 33
- 239000002184 metal Substances 0.000 claims description 33
- 230000006837 decompression Effects 0.000 claims description 9
- 238000006073 displacement reaction Methods 0.000 claims 1
- 238000010079 rubber tapping Methods 0.000 claims 1
- 230000007547 defect Effects 0.000 abstract description 13
- 238000007711 solidification Methods 0.000 abstract description 7
- 230000008023 solidification Effects 0.000 abstract description 7
- 239000002893 slag Substances 0.000 abstract description 4
- 229910052782 aluminium Inorganic materials 0.000 description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 9
- 230000000052 comparative effect Effects 0.000 description 9
- 238000013461 design Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 239000000243 solution Substances 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 4
- 229910000838 Al alloy Inorganic materials 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 239000000498 cooling water Substances 0.000 description 2
- 238000005429 filling process Methods 0.000 description 2
- 238000011056 performance test Methods 0.000 description 2
- 230000002441 reversible effect Effects 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 230000008094 contradictory effect Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 238000000265 homogenisation Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
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- 230000002195 synergetic effect Effects 0.000 description 1
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- 230000008646 thermal stress Effects 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
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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
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
-
- 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
- B22D27/13—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting by using pressure making use of gas pressure
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
The invention provides a wheel antigravity casting method, which comprises the following steps: pouring liquid into a mould, cooling, and demoulding to obtain the wheel; the mold is provided with a molding cavity and a pouring gate, wherein the inner rim part of the molding cavity corresponding to the wheel faces the gravity direction, and the outer rim part of the molding cavity corresponding to the wheel faces the gravity opposite direction; the liquid injection process comprises the following steps: a liquid lifting stage; a filling stage; a supercharging stage; a pressure maintaining stage; and a pressure release stage. According to the wheel antigravity casting method provided by the invention, the mold is reversely arranged, namely, the part of the forming cavity corresponding to the inner rim of the wheel faces the gravity direction, and the part of the forming cavity corresponding to the outer rim of the wheel faces the gravity direction, so that the wheel rim is stably filled under the double feeding of pressure and self gravity in the solidification process when being cast, and the defects of air holes, slag inclusion and the like of the wheel rim are eliminated.
Description
Technical Field
The invention relates to the technical field of wheel casting, in particular to a wheel antigravity casting method.
Background
With the rapid development of the new energy automobile industry, an aluminum alloy chassis is receiving higher and higher attention as an important component part of an automobile. In particular, the weight of the chassis has a considerable influence on the energy consumption of the motor vehicle. At present, the production process of the automobile aluminum alloy chassis part is mainly based on forging and casting technologies, and the casting technology is low in cost, so that the advantage of being suitable for more complex modeling is gradually becoming the choice of more and more host factories. Most typically, low pressure, differential pressure, antigravity casting techniques are used, which are all progressively filled upwardly from the lowermost end of the mold. However, this form is extremely prone to under-run and air pockets for thin or curved trailing end designs, such as wheels. And for the casting with the molding surface (the surface with the outer rim of the wheel) on the bottom die, the bottom die is used as a feeding channel, the temperature is higher, and the molding surface is extremely easy to corrode and adhere to aluminum. These problems greatly reduce the casting yield of aluminum alloy chassis pieces, and affect the casting quality and production cost of the products.
In view of the foregoing, there is a great need for a wheel antigravity casting method to solve the problems of the related art.
Disclosure of Invention
The invention mainly aims to provide a wheel antigravity casting method, which aims to solve the technical problems that the casting is insufficient, the air is rolled and the molding surface of a bottom die is easy to corrode and adhere aluminum in the process of casting wheels in the related technology.
In order to achieve the above object, the present invention provides a wheel antigravity casting method, comprising: pouring liquid into a mould, cooling, and demoulding to obtain the wheel; the mold is provided with a molding cavity and a pouring gate, wherein the inner rim part of the molding cavity corresponding to the wheel faces the gravity direction, and the outer rim part of the molding cavity corresponding to the wheel faces the gravity opposite direction;
The liquid injection process comprises the following steps:
And (3) liquid lifting stage: the liquid lifting time is 8-12s, the pressure is raised from 0 to 180-240mbar, and the liquid level of the molten metal is raised to the gate of the die;
And (3) a filling stage: the filling time is 20-40s, the pressure is increased from 180-240mbar to 280-380mbar, and the molten metal fills the forming cavity in the die from bottom to top;
pressurization stage: the pressurizing time is 5-12s, and the pressure is increased from 280-380mbar to 700-950mbar;
Pressure maintaining stage: dwell time is 60-180s, pressure is 700-950mbar;
Decompression stage: the pressure is reduced from 700 to 950mbar to 0 for 20 to 50 seconds.
Preferably, the mold comprises an upper mold, a first lower mold, a second lower mold, a side mold, a gate component and a water cooling component, wherein the upper mold, the first lower mold, the second lower mold and the side mold are matched to form the forming cavity, and the first lower mold and the second lower mold are matched to form a flange part of the forming cavity corresponding to the wheel; the first lower die is provided with a pouring gate, and a pouring gate component is arranged in the pouring gate along the same central axis; the upper die is provided with a diversion cone, and the diversion cone, the sprue assembly and the sprue are arranged with the central axis; the water cooling assembly comprises a plurality of water cooling pipelines which are respectively arranged on the split cone, the first lower die, the second lower die and the side die.
Preferably, the diverter cone comprises a cylindrical portion and a cone portion, wherein the cylindrical portion penetrates through the upper die, the cone portion is arranged at one end of the cylindrical portion in the forming cavity, and the cone portion extends into the sprue assembly.
Preferably, the first sprue component comprises a first sprue bush and a second sprue bush, the first sprue bush is arranged in the sprue, the second sprue bush is arranged at one end of the first sprue bush far away from the upper die and is positioned in the sprue, and the first sprue bush, the second sprue bush and the sprue are all arranged with the same central axis.
Preferably, the end face, close to the upper die, of the sprue bush is flush with the end face, close to the upper die, of the first lower die, the flow dividing cone and the sprue bush are arranged together in a central axis mode, and the cone portion of the flow dividing cone extends into the sprue bush.
Preferably, the water cooling assembly comprises 4 groups of water cooling pipelines respectively arranged on the split cone, the first lower die, the second lower die and the side die; the water cooling pipeline is an annular water cooling pipeline or a punctiform water cooling pipeline.
Preferably, the water-cooling pipeline arranged on the split cone is a point-shaped water-cooling pipeline, and the rest is an annular water-cooling pipeline or a point-shaped water-cooling pipeline.
Preferably, the cooling step comprises opening water cooling pipelines in the upper die, the first lower die, the second lower die and the side die, wherein the duration is 50s-180s, and the water flow is 100-600L/hr.
Preferably, the water cooling pipeline is 10mm-30mm away from the surface of the forming cavity, and the diameter of the water channel section is phi 10 mm-phi 20mm.
Preferably, the forming cavity is circumferentially provided with inner rim vent plugs corresponding to the inner rims of the wheels, the number of the inner rim vent plugs is 8-40, and the diameter of the inner rim vent plugs is 6-12mm; the forming cavity is circumferentially provided with outer rim vent plugs corresponding to the outer rims of the wheels, the number of the vent plugs is 8-40, and the diameter of the vent plugs is 6-12mm.
The invention has the beneficial effects that:
According to the wheel antigravity casting method provided by the invention, the mold is reversely arranged, namely, the part of the forming cavity corresponding to the inner rim of the wheel faces the gravity direction, and the part of the forming cavity corresponding to the outer rim of the wheel faces the gravity direction, so that the wheel rim is stably filled under the double feeding of pressure and self gravity in the solidification process when being cast, and the defects of air holes, slag inclusion and the like of the wheel rim are eliminated.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to the structures shown in these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic view of a mold for casting a wheel according to an embodiment of the present application;
FIG. 2 is an enlarged schematic view of the structure at the ejector ring of the mold of FIG. 1;
fig. 3 is a schematic view showing the structure of a mold for casting a wheel according to comparative example 3 of the present application.
Wherein 1-a first lower die; 2-a second lower die; 3-upper die; 4, side mold; 5-a first sprue bush; 6-a sprue bush II; 7-a split cone; 8-an ejector rod; 9-a water cooling pipeline arranged on the first lower die; 10-a water cooling pipeline arranged on the second lower die; 11-a water cooling pipeline arranged on the side die; 12-stripping ring; 13-an inner rim; 14-an outer rim; 15-wheels; 16-inner rim vent plugs; 17-an outer rim vent plug;
01-upper die of the second die; 02-a second lower die of the die; 03-two side dies 03; 04-a first pouring gate sleeve of a second die; 05-a second sprue bush of the second die; 06-a mold split cone; 07-a second ejector rod of the die; 08-a water-cooling pipeline I arranged on the upper die of the die II; 09-a water cooling pipeline II arranged on the upper die of the die II; 010-water cooling pipelines arranged on two side dies of the die; 011-a second die ring; 012-inner rim of mold two; 013-mold outer rim; 014-casting the wheel by the second mold; 015-a mold outer rim vent plug; 016-a two-die inner rim vent plug.
The achievement of the object, functional features and advantages of the present invention will be further described with reference to the drawings in connection with the embodiments.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and fully with reference to the accompanying drawings, in which it is evident that the embodiments described are only some, but not all embodiments of the invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the present invention without making any inventive effort, are intended to fall within the scope of the present invention.
It should be noted that all directional indicators (such as upper and lower … …) in the embodiments of the present invention are merely used to explain the relative positional relationship, movement conditions, etc. between the components in a particular posture, and if the particular posture is changed, the directional indicators are changed accordingly.
Furthermore, descriptions such as those referred to as "first," "second," and the like, are provided for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implying an order of magnitude of the indicated technical features in the present disclosure. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature.
Moreover, the technical solutions of the embodiments of the present invention may be combined with each other, but it is necessary to be based on the fact that those skilled in the art can implement the embodiments, and when the technical solutions are contradictory or cannot be implemented, it should be considered that the combination of the technical solutions does not exist, and is not within the scope of protection claimed by the present invention.
The invention provides a wheel antigravity casting method, which comprises the following steps: pouring liquid into a mould, cooling, and demoulding to obtain the wheel; the mold is provided with a molding cavity and a pouring gate, wherein the inner rim part of the molding cavity corresponding to the wheel faces the gravity direction, and the outer rim part of the molding cavity corresponding to the wheel faces the gravity opposite direction;
The liquid injection process comprises the following steps:
And (3) liquid lifting stage: the liquid lifting time is 8-12s, the pressure is increased from 0 to 180-240mbar, and the liquid level of the molten metal is increased to the pouring gate of the mould (namely the upper end of the pouring gate sleeve);
The excessive pressure can lead to the liquid lifting speed to be too fast and lead to the splashing of the molten metal, the quality of the wheel is affected, the excessive pressure can lead to the liquid lifting speed to be too slow, and the molten metal is solidified when the wheel is not formed, so that in the process, the pressure is increased from 0 to 180 to 240mbar within 8 to 12 seconds after the liquid lifting stage is started, and the molten metal is increased to the pouring gate of the die under the action of the pressure.
And (3) a filling stage: the filling time is 20-40s, the pressure is increased from 180-240mbar to 280-380mbar, and the molten metal fills the forming cavity in the die from bottom to top;
The excessive filling pressure can cause high filling speed, so that the molten metal generates vortex in the filling process, and the defects of oxidization, air suction and the like are generated, thereby influencing the quality of the wheel; the filling speed is low due to the fact that the filling pressure is too small, so that the molten metal cannot completely fill the cavity, defects such as air holes and shrinkage holes are formed, the quality of the wheel is affected, defects such as cold shut, rough surface and the like are formed, and the appearance quality of the wheel is affected; meanwhile, the casting period can be prolonged and the production efficiency can be reduced due to too low mold filling speed. Therefore, during the filling process, the pressure is increased from 180 to 240mbar to 280 to 380mbar within 20 to 40 seconds after the start of the filling stage.
Pressurization stage: the pressurizing time is 5-12s, and the pressure is increased from 280-380mbar to 700-950mbar;
The excessive pressurizing pressure causes that molten metal flows fast in the casting mould, so that the defects of rough surface, convex hulls and the like are easily formed, the appearance quality of the wheel is influenced, and the post-treatment cost is high; the small pressurizing pressure causes the defects of air holes, looseness and the like in the solidification process of the molten metal, and influences the density and the strength of the wheel, so that the performance of the wheel cannot meet the expected requirement. The pressure is thus increased from 280 to 380mbar to 700 to 950mbar within 5 to 12 seconds after the start of the boost stage.
Pressure maintaining stage: dwell time is 60-180s, pressure is 700-950mbar;
the state of the metal material during solidification can be maintained through the pressure maintaining stage, so that the defects of shrinkage cavity, shrinkage porosity and the like in the process of reducing the temperature of the molten metal are avoided; and the internal porosity of the material can be reduced in the pressure maintaining stage, so that the metallographic structure of the material is more compact, and the mechanical properties of the material, such as toughness, strength, rigidity and the like, are improved. Promoting the homogenization of the grains, preventing the deformation, separation and destruction of the material, avoiding cracks and defects in the material, ensuring the stability and reliability of the product quality, and maintaining the pressure for 60-180s after the start of this stage, since the proper dwell time and proper pressure are important indicators for achieving the above effects.
Decompression stage: the pressure is reduced from 700 to 950mbar to 0 for 20 to 50 seconds.
The wheel is solidified and formed at this stage, the pressure in the system needs to be released, and the pressure in the system can be released through pressure relief, so that the influence of overlarge pressure on the surface quality of the wheel and the service life of the die is avoided, and the subsequent demolding and other processes are facilitated. In the application, as part of the wheel is thinner, and the mold has partial pressure on the wheel, if the pressure is released too fast, the cast wheel can lose support, and the wheel is deformed, so that the pressure is reduced from 700 to 950mbar to 0 within 20 to 50 seconds after the pressure release stage begins.
In some embodiments, the mold comprises an upper mold, a first lower mold, a second lower mold, a side mold, a gate component and a water cooling component, wherein the upper mold, the first lower mold, the second lower mold and the side mold are all in profiling design, the upper mold, the first lower mold, the second lower mold and the side mold are matched to form a forming cavity for casting the wheel, wherein the first lower mold and the second lower mold are matched to form a flange part (the first lower mold and the second lower mold are welded or connected through bolts) of the corresponding forming cavity to the wheel, and the annular water cooling arranged in the inner parts of the upper mold, the first lower mold and the second lower mold have small influence on each other due to no integral molding, so that the integral cooling control of the wheel is facilitated; the first lower die is provided with a pouring gate, and a pouring gate component is arranged in the pouring gate along the same central axis; the upper die is provided with a diversion cone, and the diversion cone, the sprue assembly and the sprue are arranged with the central axis; the water cooling assembly comprises a plurality of water cooling pipelines which are respectively arranged on the split cone, the first lower die, the second lower die and the side die.
The profiling design refers to the process of measuring and recording elements such as shapes, structures, characteristics and the like of the existing physical objects or models, re-integrating the elements by applying design principles and skills, and creating new products which are similar but innovative.
According to the wheel antigravity casting method provided by the invention, through the mode that the die is reversely arranged, namely, the part of the forming cavity corresponding to the inner rim of the wheel faces the gravity direction, and the part of the forming cavity corresponding to the outer rim of the wheel faces the gravity direction, the dual feeding of pressure and self gravity can be realized in the solidification process when the wheel is cast, so that the defects of air holes, slag inclusion and the like of the rim are eliminated.
In some embodiments, the diverter cone includes a cylindrical portion disposed through the upper die and a tapered portion disposed at one end of the cylindrical portion within the molding cavity and extending into the gate assembly.
In some embodiments, the first sprue assembly includes a first sprue bush and a second sprue bush, the first sprue bush is disposed in the sprue, the second sprue bush is disposed at one end of the first sprue bush away from the upper die and is located in the sprue, and the first sprue bush, the second sprue bush and the sprue are all disposed with the same central axis (in the liquid lifting stage, the liquid level of the molten metal is lifted to the upper end of the first sprue bush of the die). Because the aluminum liquid flows in the pouring gate and can rub with the inner wall of the pouring gate, the aluminum liquid flows in the pouring gate sleeve I and the pouring gate sleeve II by arranging the pouring gate sleeve I and the pouring gate sleeve II, and when the pouring gate sleeve I or the pouring gate sleeve II is seriously worn, the aluminum liquid can be conveniently replaced.
In some embodiments, the end surface of the sprue bush I close to the upper die is flush with the end surface of the first lower die close to the upper die, the flow diversion cone and the sprue bush are arranged together with the central axis, and the cone part of the flow diversion cone extends into the sprue bush I.
The effect of the split cone in the casting mould is to change the flow direction of molten metal, so that the molten metal can be uniformly distributed in the whole cavity when entering the cavity from the sprue. The split cone is matched with the sprue bush I, and the cone part of the split cone extends into the cavity of the sprue bush I. The flow dividing cone comprises the cylindrical part and the cone part, the cone part faces the pouring gate, the flow path of molten metal can be effectively controlled, the defects of air holes, shrinkage porosity and the like are avoided, and the quality and the forming effect of the wheel are improved. In addition, the area of the tail end of the sprue can be adjusted by utilizing the dimensional change of the flow dividing cone, so that the molten metal is prevented from directly punching the wall when entering the cavity, excessive molten metal is prevented from being gathered at the bottom of the sprue, and the molten metal flows stably at the corner.
In some embodiments, the water cooling assembly comprises 4 groups of water cooling pipelines respectively arranged on the split cone, the first lower die, the second lower die and the side die; the water cooling pipeline is an annular water cooling pipeline or a punctiform water cooling pipeline.
In some embodiments, the water-cooling pipelines arranged on the split cone are point-shaped water-cooling pipelines, and the rest are annular water-cooling pipelines or point-shaped water-cooling pipelines.
In some embodiments, the cooling step includes opening water cooling lines in the upper mold, the first lower mold, the second lower mold, and the side mold for a duration of 50s-180s with a water flow rate of 100-600L/hr.
In some embodiments, the water-cooled pipeline is 10-30mm from the surface of the forming cavity, and the water channel section diameter is phi 10-phi 20mm.
After casting is finished, a cooling water channel is opened, heat generated in the solidification process of the casting can be taken away through the flow of the cooling water channel, the casting is helped to be rapidly cooled and shaped, and the cooling time of the casting is shortened, so that the whole production period is shortened. Meanwhile, the cooling waterway is opened, so that the thermal stress of the casting can be reduced, and the generation of hot cracks is prevented; and the cooling uniformity can be improved, and the cooling speed of the casting can be controlled by controlling the water flow, so that the quality and stability of the casting are improved.
In some embodiments, the mold stripping device further comprises a mold stripping ring, wherein the mold stripping ring is arranged on the upper mold, the mold stripping ring comprises a straight line section and a mold stripping section (the straight line section and the mold stripping section are integrally formed), the mold stripping ring is positioned in the outer rim part of the corresponding wheel of the molding cavity, and the mold stripping ring and the molding cavity are arranged with the same central axis. The stripping section of the stripping ring forms an included angle with the central axis direction of the stripping section, and the angle is-5 degrees to 5 degrees; the straight line section of the die-sinking mechanism has no included angle with the central axis direction, the length is 3mm to 15mm, the casting can be lifted along with the upper die when the die-sinking ring is used for die sinking, and the upper die has better heat dissipation and low temperature, so that aluminum is not easy to adhere, the quality of the casting is improved, and in addition, the casting is not easy to scratch along with the movement of the upper die.
In some embodiments, the forming cavity is circumferentially provided with inner rim vent plugs corresponding to the inner rims of the wheels, the number of the inner rim vent plugs is 8-40, and the diameter of the forming cavity is 6-12mm; the forming cavity is circumferentially provided with outer rim vent plugs corresponding to the outer rims of the wheels, the number of the vent plugs is 8-40, and the diameter of the vent plugs is 6-12mm.
Furthermore, the vent plugs are uniformly arranged on the inner rim of the wheel corresponding to the forming cavity and the outer rim of the wheel corresponding to the forming cavity, so that the gas in the forming cavity can be effectively discharged through the vent plugs, and the phenomena of gas coiling and insufficient pouring are avoided.
In some embodiments, the upper die is further provided with a plurality of ejector rods therethrough. The ejector rod can be used for demolding the wheel.
Examples
The present disclosure is more particularly described in the following examples that are intended as illustrations only, since various modifications and changes within the scope of the present disclosure will be apparent to those skilled in the art. Unless otherwise indicated, all parts, percentages, and ratios reported in the examples below are by weight, and all reagents used in the examples are commercially available or were obtained synthetically according to conventional methods and can be used directly without further treatment, as well as the instruments used in the examples.
Example 1: the invention provides a wheel antigravity casting method, which comprises the following steps: pouring liquid (aluminum liquid) into the mould, cooling, and demoulding to obtain the wheel; the temperature of the aluminum liquid is 680-720 ℃ (700 ℃ in the embodiment), and the density is 2.67g/cm 3, wherein a forming cavity and a pouring gate are arranged in the die, the part of the forming cavity corresponding to the inner rim 13 of the wheel faces the gravity direction, and the part of the forming cavity corresponding to the outer rim 14 of the wheel faces the gravity opposite direction;
The liquid injection process comprises the following steps:
And (3) liquid lifting stage: the liquid lifting time is 10s, the pressure is raised from 0 to 220mbar, and the liquid level of the molten metal is raised to the upper end of a sprue bush of the die;
And (3) a filling stage: the filling time is 28s, the pressure is increased from 200mbar to 320mbar, and the molten metal fills the forming cavity in the die from bottom to top;
pressurization stage: pressurizing time is 8s, and the pressure is increased from 320mbar to 850mbar;
pressure maintaining stage: dwell time 110s, pressure 850mbar;
decompression stage: the pressure was reduced from 850mbar to 0 for 35 s.
In this embodiment, referring to fig. 1, the mold includes an upper mold 3, a first lower mold 1, a second lower mold 2, a side mold 4, a gate component and a water cooling component, where the upper mold 3, the first lower mold 1, the second lower mold 2 and the side mold 4 are all profiled, and the upper mold 3, the first lower mold 1, the second lower mold 2 and the side mold 4 are matched to form a molding cavity for casting a wheel, where the first lower mold 1 and the second lower mold 2 are matched to form a molding cavity corresponding to a flange portion of the wheel (the first lower mold and the second lower mold are welded), the molding cavity corresponding to an inner rim portion of the wheel faces in a gravity direction, and the molding cavity corresponding to an outer rim portion of the wheel faces in a gravity opposite direction; the first lower die is provided with a pouring gate, and a pouring gate component is arranged in the pouring gate along the same central axis; the upper die is provided with a diverter cone 7, and the diverter cone 7, the sprue assembly and the sprue are arranged with the central axis; the water cooling assembly comprises 4 groups of water cooling pipelines which are respectively arranged on the split cone 7, the first lower die, the second lower die and the side die; the water cooling pipelines arranged on the split cone are punctiform water cooling pipelines, and the rest are annular water cooling pipelines.
In this embodiment, the tap includes a cylindrical portion that is disposed through the upper die, and a tapered portion that is disposed at one end of the cylindrical portion in the molding cavity and that extends into the gate assembly.
In this embodiment, the gate assembly includes a first gate sleeve 5 and a second gate sleeve 6, the first gate sleeve 5 is disposed in the gate, the second gate sleeve 6 is disposed at one end of the first gate sleeve 5 far away from the upper die and is located in the gate, and the first gate sleeve, the second gate sleeve and the gate are all disposed with the same central axis.
In this embodiment, the end face of the first sprue bush close to the upper die is flush with the end face of the first lower die close to the upper die, the split cone and the sprue bush are arranged together with the central axis, and the cone part of the split cone extends into the first sprue bush.
In this embodiment, the cooling step includes opening water-cooling pipelines in the split cone, the first lower die, the second lower die and the side die, where the cooling time of the water-cooling pipeline is set in the split cone: 90-140s, water flow rate 300L/hr; cooling time of the water cooling pipeline 9 arranged on the first lower die: 110-160s, water flow rate 300L/hr; cooling time of the water cooling pipeline 10 arranged on the second lower die: 0-50s, water flow rate 200L/hr; cooling time of the water cooling pipeline 11 arranged on the side die: 10-150s, water flow rate 200L/hr.
In the embodiment, the water cooling pipeline is 20mm away from the surface of the forming cavity, and the diameter of the water channel section is phi 10mm.
In this embodiment, referring to fig. 2, the mold stripping device further includes a mold stripping ring 12, where the mold stripping ring 12 is disposed on the upper mold, the mold stripping ring includes a straight line segment and a mold stripping segment, and the mold stripping ring is located in the molding cavity corresponding to the outer rim portion of the wheel and is disposed with the molding cavity along the same central axis. The stripping section of the stripping ring forms an included angle with the central axis direction of the stripping section, and the angle is-5 degrees; the straight line section has no included angle with the central axis direction, and the length is 7mm.
In the embodiment, the inner rim of the forming cavity corresponding to the wheel is circumferentially provided with inner rim vent plugs 16, the number of which is 16, and the diameter of which is 8mm; the forming cavity is circumferentially provided with outer rim vent plugs 17 corresponding to the outer rims of the wheels, the number of the vent plugs is 16, and the diameter of the vent plugs is 8mm.
In this embodiment, the upper die is further provided with an ejector rod 8 penetrating therethrough.
Example 2: the difference from example 1 is that:
The liquid injection process comprises the following steps:
And (3) liquid lifting stage: the liquid lifting time is 10s, the pressure is raised from 0 to 220mbar, and the liquid level of the molten metal is raised to the upper end of a sprue bush of the die;
And (3) a filling stage: the filling time is 35s, the pressure is increased from 120mbar to 350mbar, and the molten metal fills the forming cavity in the die from bottom to top;
Pressurization stage: pressurizing time is 10s, and the pressure is increased from 350mbar to 950mbar;
Pressure maintaining stage: dwell time 130s, pressure 950mbar;
Decompression stage: the pressure was reduced from 950mbar to 0 for a pressure release time of 30 s.
In this embodiment, the cooling step includes opening water-cooling pipelines in the split cone, the first lower die, the second lower die and the side die, where the cooling time of the water-cooling pipeline is set in the split cone: 100-150s, water flow rate 300L/hr; ; the water cooling pipeline cooling time of the first lower die is set up: 120-170s, water flow rate 300L/hr; and the cooling time of the water cooling pipeline arranged on the second lower die is as follows: 10-50s, water flow rate 200L/hr; and the cooling time of the water cooling pipeline of the side die is as follows: 20-140s, and water flow rate of 200L/hr.
Example 3: the difference from example 1 is that:
The liquid injection process comprises the following steps:
And (3) liquid lifting stage: the liquid lifting time is 10s, the pressure is raised from 0 to 220mbar, and the liquid level of the molten metal is raised to the upper end of a sprue bush of the die;
And (3) a filling stage: the filling time is 23s, the pressure is increased from 220mbar to 280mbar, and the molten metal fills the forming cavity in the die from bottom to top;
pressurization stage: pressurizing time is 10s, and the pressure is increased from 280mbar to 750mbar;
Pressure maintaining stage: dwell time 90s, pressure 750mbar;
Decompression stage: the pressure was reduced from 750mbar to 0 for a pressure release time of 40 s.
In this embodiment, the cooling step includes opening water-cooling pipelines in the split cone, the first lower die, the second lower die and the side die, where the cooling time of the water-cooling pipeline is set in the split cone: 80-140s, water flow rate 300L/hr; the water cooling pipeline cooling time of the first lower die is set up: 90-140s, water flow rate 300L/hr; and the cooling time of the water cooling pipeline arranged on the second lower die is as follows: 0-60s, water flow rate 200L/hr; and the cooling time of the water cooling pipeline of the side die is as follows: 10-130s, water flow rate 300L/hr.
Comparative example 1: the difference from example 1 is that:
The liquid injection process comprises the following steps:
And (3) liquid lifting stage: the liquid lifting time is 10s, the pressure is raised from 0 to 220mbar, and the liquid level of the molten metal is raised to the upper end of a sprue bush of the die;
And (3) a filling stage: the filling time is 30s, the pressure is increased from 220mbar to 400mbar, and the molten metal fills the forming cavity in the die from bottom to top;
Pressurization stage: pressurizing time is 8s, and the pressure is increased from 400mbar to 970mbar;
Pressure maintaining stage: dwell time 80s, pressure 970mbar;
decompression stage: the pressure was reduced from 970mbar to 0 for a pressure release time of 40 s.
In this embodiment, the cooling step includes opening water-cooling pipelines in the split cone, the first lower die, the second lower die and the side die, where the cooling time of the water-cooling pipeline is set in the split cone: 60-130s, water flow rate 300L/hr; the water cooling pipeline cooling time of the first lower die is set up: 60-130s, water flow rate 300L/hr; and the cooling time of the water cooling pipeline arranged on the second lower die is as follows: 0-100s, water flow rate 300L/hr; and the cooling time of the water cooling pipeline of the side die is as follows: 10-130s, water flow rate 300L/hr.
Comparative example 2: the difference from example 1 is that:
The liquid injection process comprises the following steps:
And (3) liquid lifting stage: the liquid lifting time is 10s, the pressure is raised from 0 to 220mbar, and the liquid level of the molten metal is raised to the upper end of a sprue bush of the die;
and (3) a filling stage: the filling time is 25s, the pressure is increased from 220mbar to 250mbar, and the molten metal fills the forming cavity in the die from bottom to top;
pressurization stage: pressurizing time is 10s, and the pressure is increased from 300mbar to 650mbar;
Pressure maintaining stage: dwell time 150s, pressure 650mbar;
decompression stage: the pressure was reduced from 650mbar to 0 for a pressure release time of 30 s.
In this embodiment, the cooling step includes opening water-cooling pipelines in the split cone, the first lower die, the second lower die and the side die, where the cooling time of the water-cooling pipeline is set in the split cone: 80-190s, water flow rate 300L/hr; the water cooling pipeline cooling time of the first lower die is set up: 80-190s, water flow rate 300L/hr; and the cooling time of the water cooling pipeline arranged on the second lower die is as follows: 0-80s, water flow rate 200L/hr; and the cooling time of the water cooling pipeline of the side die is as follows: 10-160s, water flow rate 200L/hr.
Comparative example 3: a method of wheel antigravity casting comprising: and (3) pouring liquid (aluminum liquid, the temperature is 700 ℃, the density is 2.67g/cm 3) into a second mold, cooling and demolding to obtain the wheel 014, wherein the second mold is provided with a molding cavity and a pouring gate, the part of the molding cavity, corresponding to the second mold inner rim 012 of the wheel, faces the gravity opposite direction, and the part, corresponding to the outer mold rim 013 of the wheel, faces the gravity direction.
The liquid injection process comprises the following steps:
And (3) liquid lifting stage: the liquid lifting time is 10s, the pressure is raised from 0 to 200mbar, and the liquid level of the molten metal is raised to the upper end of the sprue bush I of the second die;
And (3) a filling stage: the filling time is 30s, the pressure is increased from 200mbar to 340mbar, and the molten metal fills the forming cavity in the die from bottom to top;
Pressurization stage: pressurizing time is 8s, and the pressure is increased from 300mbar to 850mbar;
Pressure maintaining stage: dwell time 180s, pressure 850mbar;
decompression stage: the pressure was reduced from 850mbar to 0 for a pressure release time of 40 s.
Referring to fig. 3, the second mold comprises a second upper mold 01, a second lower mold 02, a second side mold 03, a second gate component and a second water cooling component, wherein the second upper mold 01, the second first lower mold, the second lower mold and the second side mold 03 are all in profiling design, and the second upper mold 01, the second lower mold 02 and the second side mold 03 are matched to form a molding cavity for casting the wheel; the second lower die 02 is provided with a gate, and a second gate component is arranged in the gate and on the central axis; the second upper die 01 is provided with a die shunt cone 06, and the die shunt cone 06, the second pouring gate component and the second pouring gate are arranged on the same central axis; the second water cooling component of the die comprises 4 groups of water cooling pipelines respectively arranged on the die split cone 06, the second upper die 01 and the second side die 03, wherein the water cooling pipeline arranged on the die split cone 06 is a punctiform water cooling pipeline, the first water cooling pipeline and the second water cooling pipeline arranged on the second upper die 01 are annular water cooling pipelines, and the water cooling pipeline arranged on the second side die 03 is an annular water cooling pipeline.
In this embodiment, the mold split cone includes a cylindrical portion and a conical portion, the cylindrical portion is disposed through the upper mold, the conical portion is disposed at one end of the cylindrical portion in the molding cavity, and the conical portion extends into the second gate component of the mold.
In this embodiment, the second gate component includes a first second gate sleeve 04 and a second gate sleeve 05, the first second gate sleeve 04 is disposed in the second gate, the second gate sleeve 05 is disposed at one end of the first second gate sleeve 04 far away from the second upper die 01 and is disposed in the second gate, and the first second gate sleeve 04, the second gate sleeve 05 and the second gate are all disposed with the same central axis.
In this embodiment, the end surface of the first die second sprue bush 04 close to the upper die 01 of the die second is flush with the end surface of the second die lower die 02 close to the upper die of the die second, the die split cone and the first die second sprue bush 04 are arranged with the same central axis, and the cone part of the die split cone extends into the first die second sprue bush 04.
In this embodiment, the cooling step includes opening water-cooling pipelines in the mold split cone, the mold two upper mold 01 and the mold two side mold 03, where the cooling time of the water-cooling pipeline is set in the mold split cone: 50-55s, water flow rate 300L/hr; and the first 08 cooling time of the water cooling pipeline arranged on the second upper die of the die is as follows: 40-45s, water flow rate 300L/hr; and the cooling time of a water cooling pipeline II 09 arranged on the upper die II is as follows: 0-20s, water flow rate 200L/hr; the cooling time of the water cooling pipeline 010 arranged on the two side dies of the die is as follows: 120-130s, water flow rate 200L/hr.
In the embodiment, the water cooling pipeline is 20mm away from the surface of the forming cavity, and the diameter of the water channel section is phi 10mm.
In this embodiment, the mold further includes a mold second ejector ring 011, where the mold second ejector ring 011 is disposed on the upper mold, and the mold second ejector ring includes a straight line segment and an ejector segment, where the mold second ejector ring is located at a position where the molding cavity corresponds to the outer rim portion of the mold of the wheel and where the mold second ejector ring and the molding cavity are disposed with the same central axis. The ejector section of the second ejector ring of the die forms an included angle with the central axis direction of the second ejector ring, and the angle is-5 degrees; the straight line section has no included angle with the central axis direction, and the length is 7mm.
In the embodiment, the second inner rim of the mold corresponding to the wheel in the molding cavity is circumferentially provided with 16 second inner rim vent plugs 016 with the diameter of 8mm; the outer rim circumference of mould that the shaping chamber corresponds the wheel is provided with the outer rim vent plug 015 of mould, and 16 in quantity, diameter 8mm.
In this embodiment, the upper mold is further provided with a mold two ejector rod 07.
The cast wheels of examples 1 to 3 and comparative examples 1 to 3 were subjected to performance tests (GB/T228-2002 tensile test elongation test, yield statistics, surface property defect statistics, etc.), and the results are shown in Table 1:
TABLE 1 results of Performance test of wheels cast from examples 1-3 and comparative examples 1-3
From the results of examples 1 to 3 and comparative examples 1 to 2, it is understood that the yield of the wheel is significantly improved when the pressure value and time of each stage in the injection process are within the preferable ranges, and the yield is significantly reduced when the pressure value and time of one or more stages are outside the preferable ranges. The pressure parameter selection of each stage in the liquid injection process has a synergistic effect.
As is clear from the results of examples 1 to 3 and comparative example 3, the mold was in a reverse form (i.e., the inner rim portion of the mold cavity corresponding to the wheel was oriented in the direction of gravity and the outer rim portion of the mold cavity corresponding to the wheel was oriented in the opposite direction of gravity), and the cast wheel was higher in yield, which was 95.8% at the maximum, whereas comparative example 3 was 91.8% in yield, and the flying waste rate during the subsequent polishing treatment was 2%. The die can effectively realize double feeding of pressure and self gravity to the rim in the solidification process when the wheel is cast in a reverse mode, so that the defects of air holes, slag inclusion and the like of the rim are overcome, and the yield is improved.
In the above technical solution of the present invention, the above is only a preferred embodiment of the present invention, and therefore, the patent scope of the present invention is not limited thereto, and all the equivalent structural changes made by the description of the present invention and the content of the accompanying drawings or the direct/indirect application in other related technical fields are included in the patent protection scope of the present invention.
Claims (10)
1. A method of countergravity casting of a wheel, comprising: pouring liquid into a mould, cooling, and demoulding to obtain the wheel; the mold is provided with a molding cavity and a pouring gate, wherein the inner rim part of the molding cavity corresponding to the wheel faces the gravity direction, and the outer rim part of the molding cavity corresponding to the wheel faces the gravity opposite direction;
The liquid injection process comprises the following steps:
And (3) liquid lifting stage: the liquid lifting time is 8-12s, the pressure is raised from 0 to 180-240mbar, and the liquid level of the molten metal is raised to the gate of the die;
And (3) a filling stage: the filling time is 20-40s, the pressure is increased from 180-240mbar to 280-380mbar, and the molten metal fills the forming cavity in the die from bottom to top;
pressurization stage: the pressurizing time is 5-12s, and the pressure is increased from 280-380mbar to 700-950mbar;
Pressure maintaining stage: dwell time is 60-180s, pressure is 700-950mbar;
Decompression stage: the pressure is reduced from 700 to 950mbar to 0 for 20 to 50 seconds.
2. The method of antigravity casting of a wheel according to claim 1, wherein the mold comprises an upper mold (3), a first lower mold (1), a second lower mold (2), a side mold (4), a gate component and a water cooling component, the upper mold (3), the first lower mold (1), the second lower mold (2) and the side mold (4) being mated to form the molding cavity, wherein the first lower mold (1) and the second lower mold (2) are mated to form a flange portion of the molding cavity corresponding to the wheel; the first lower die (1) is provided with a pouring gate, and a pouring gate component is arranged in the pouring gate along the same central axis; the upper die (3) is provided with a flow dividing cone (7), and the flow dividing cone (7), the pouring gate component and the pouring gate are arranged on the same central axis; the water cooling assembly comprises a plurality of water cooling pipelines which are respectively arranged on the split cone (7), the first lower die (1), the second lower die (2) and the side die (4).
3. The wheel antigravity casting method according to claim 2, wherein the tapping cone (7) comprises a cylindrical portion disposed through the upper die (3) and a cone portion disposed at one end of the cylindrical portion within the molding cavity and extending into the gate assembly.
4. A wheel antigravity casting method according to claim 3 wherein the sprue assembly comprises a first sprue bush (5) and a second sprue bush (6), the first sprue bush (5) being arranged in the sprue, the second sprue bush (6) being arranged at one end of the first sprue bush (5) remote from the upper die (3) and in the sprue, the first sprue bush (5), the second sprue bush (6) and the sprue being all arranged with the same central axis.
5. The wheel antigravity casting method according to claim 4, wherein an end face of the first sprue bush (5) close to the upper die (3) is flush with an end face of the first lower die (1) close to the upper die (3), the split cone and the first sprue bush (5) are coaxially arranged, and a cone portion of the split cone extends into the first sprue bush (5).
6. The method for casting the wheel according to claim 2, wherein the water cooling assembly comprises 4 groups of water cooling pipelines respectively arranged on the split cone, the first lower die (1), the second lower die (2) and the side die (4); the water cooling pipeline is an annular water cooling pipeline or a punctiform water cooling pipeline.
7. The method according to claim 6, wherein the water-cooling pipes provided in the split cone are dot-shaped water-cooling pipes, and the rest are ring-shaped water-cooling pipes or dot-shaped water-cooling pipes.
8. The method of claim 6, wherein the cooling step comprises opening water cooling lines in the split cone, the first lower die (1), the second lower die (2), and the side die (4) for a duration of 50s-180s at a water flow rate of 100-600L/hr.
9. The method of claim 6, wherein the water-cooled pipeline is 10mm-30mm from the surface of the molding cavity, and the water channel has a cross-sectional diameter of 10 mm-20 mm.
10. The wheel antigravity casting method according to any one of claims 1 to 9, wherein the forming cavity is circumferentially provided with inner rim air displacement plugs (16) corresponding to the inner rim of the wheel, the number of which is 8 to 40, and the diameter of which is 6 to 12mm; the forming cavity is circumferentially provided with outer rim vent plugs (17) corresponding to the outer rims of the wheels, the number of the vent plugs is 8-40, and the diameter of the vent plugs is 6-12mm.
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| CN202410083851.0A CN117900423A (en) | 2024-01-19 | 2024-01-19 | Wheel antigravity casting method |
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| CN202410083851.0A CN117900423A (en) | 2024-01-19 | 2024-01-19 | Wheel antigravity casting method |
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