CN115464112A - Ultra-large cylinder sleeve accurate water-cooling temperature-control centrifugal casting device and casting method - Google Patents
Ultra-large cylinder sleeve accurate water-cooling temperature-control centrifugal casting device and casting method Download PDFInfo
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- CN115464112A CN115464112A CN202211129176.8A CN202211129176A CN115464112A CN 115464112 A CN115464112 A CN 115464112A CN 202211129176 A CN202211129176 A CN 202211129176A CN 115464112 A CN115464112 A CN 115464112A
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- 238000005266 casting Methods 0.000 title claims abstract description 130
- 238000001816 cooling Methods 0.000 title claims abstract description 71
- 238000000034 method Methods 0.000 title claims abstract description 42
- 238000009750 centrifugal casting Methods 0.000 title claims abstract description 40
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 111
- 238000005507 spraying Methods 0.000 claims abstract description 42
- 239000007921 spray Substances 0.000 claims abstract description 26
- 238000007711 solidification Methods 0.000 claims abstract description 25
- 230000008023 solidification Effects 0.000 claims abstract description 25
- 238000004364 calculation method Methods 0.000 claims abstract description 17
- 238000009826 distribution Methods 0.000 claims abstract description 13
- 239000000463 material Substances 0.000 claims abstract description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 132
- 239000000498 cooling water Substances 0.000 claims description 85
- 229910052742 iron Inorganic materials 0.000 claims description 66
- 238000004088 simulation Methods 0.000 claims description 24
- 230000007547 defect Effects 0.000 claims description 10
- 238000002474 experimental method Methods 0.000 claims description 4
- 238000007599 discharging Methods 0.000 claims description 3
- 238000012544 monitoring process Methods 0.000 claims 2
- 238000012806 monitoring device Methods 0.000 claims 1
- 238000005204 segregation Methods 0.000 abstract description 7
- 238000002360 preparation method Methods 0.000 abstract description 4
- 230000000694 effects Effects 0.000 description 11
- 238000004519 manufacturing process Methods 0.000 description 7
- 239000000203 mixture Substances 0.000 description 5
- 238000009529 body temperature measurement Methods 0.000 description 4
- 238000007689 inspection Methods 0.000 description 4
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000956 alloy Substances 0.000 description 3
- 230000001276 controlling effect Effects 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 238000005119 centrifugation Methods 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 238000011897 real-time detection Methods 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000003643 water by type Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D13/00—Centrifugal casting; Casting by using centrifugal force
- B22D13/12—Controlling, supervising, specially adapted to centrifugal casting, e.g. for safety reasons
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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
- B22D13/00—Centrifugal casting; Casting by using centrifugal force
- B22D13/02—Centrifugal casting; Casting by using centrifugal force of elongated solid or hollow bodies, e.g. pipes, in moulds rotating around their longitudinal axis
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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
- B22D13/00—Centrifugal casting; Casting by using centrifugal force
- B22D13/10—Accessories for centrifugal casting apparatus, e.g. moulds, linings therefor, means for feeding molten metal, cleansing moulds, removing castings
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Abstract
An ultra-large cylinder sleeve accurate water-cooling temperature control centrifugal casting device and a casting method relate to a casting device and a casting method. The invention aims to solve the problems of thermal budget, segregation and shrinkage porosity of the cylinder sleeve caused by difficulty in realizing simultaneous solidification in the preparation of the existing cylinder sleeve. The invention has the advantages that a plurality of groups of rotating wheels are divided into two rows and symmetrically arranged on a base, a bushing is arranged on the plurality of groups of rotating wheels, a mould is embedded in the bushing, the front end and the rear end of the mould are respectively connected through a front end cover and a rear end cover, and a plurality of water spray cooling units are arranged on the outer circumference of the bushing in an encircling manner. The invention selects casting and casting materials, reasonably sets centrifugal casting process parameters, and carries out modeling calculation on the centrifugal casting process. According to the obtained temperature field distribution results of the casting and the casting mold, the water path arrangement and the water spraying time of the water spraying ring are designed, so that the casting is solidified simultaneously as much as possible. The invention is used for the accurate water-cooling temperature control centrifugal casting of the cylinder sleeve.
Description
Technical Field
The invention relates to a centrifugal casting device and a casting method, in particular to an ultra-large cylinder sleeve accurate water-cooling temperature-control centrifugal casting device and a casting method, and belongs to the field of casting equipment.
Background
The ultra-large cylinder sleeve (the cylinder diameter is 270mm-400mm, the thinnest is 50mm, and the thickest is 149 mm) is an important part of a large medium-speed ship engine, a piston does reciprocating motion in the cylinder sleeve to form a combustion chamber of the engine together, and the service environment of the engine needs to bear high temperature and repeated friction and impact, so that the requirement on the high-temperature mechanical property of the cylinder sleeve is extremely high. Therefore, the requirements on the structure of the cylinder sleeve are extremely high, and the defects of thermal nodes, segregation, shrinkage cavities, shrinkage porosity and the like are reduced as much as possible in the preparation production process.
At present, the cooling process of the cylinder sleeve is mostly water spray cooling on a die integrally, the wall thickness of the cylinder sleeve is uneven and large in size, an internal temperature field and a flow field cannot be known when a casting is filled and solidified in the actual production process, and simultaneous solidification is difficult to realize, so that the cylinder sleeve has the defects of heat section, segregation and shrinkage porosity due to the fact that the distribution and flow design of cooling water is difficult. With the rise of computer simulation software, the problem can be well solved by simulating the temperature field and the flow field of the molten metal in the filling and solidifying processes by means of numerical simulation software.
The existing method for improving the mechanical property of the cylinder sleeve is mainly started from the components of the alloy, and the structure of the alloy is regulated and controlled, for example, the carburization (application number: 201310539083.7) and the regulation and control of the components of the alloy (application number: 201910925882.5) are adopted. The methods have long experimental period and high cost, are not suitable for ultra-large cylinder sleeves on marine engine machines, and can not solve the problem that the cylinder sleeves can not be solidified simultaneously.
In conclusion, the existing cylinder sleeve is difficult to solidify at the same time during preparation, so that the problems of thermal shrinkage, segregation and shrinkage porosity of the cylinder sleeve exist.
Disclosure of Invention
The invention aims to solve the problems of thermal junctions, segregation and shrinkage porosity of a cylinder sleeve caused by difficulty in realizing simultaneous solidification in the preparation of the conventional cylinder sleeve. Further provides an accurate water-cooling temperature-control centrifugal casting device and a casting method for the ultra-large cylinder sleeve.
The technical scheme of the invention is as follows: the utility model provides an accurate water-cooling accuse temperature centrifugation casting device of ultra-large cylinder liner is including watering the package, and it still includes base, multiunit runner, motor, pivot, bush, mould, front end housing, a plurality of water spray cooling unit and rear end housing, and the multiunit runner divide into two and the symmetry is installed on the base, and the motor is connected through pivot and one of them group runner, a set of runner is initiative runner, and the bush is installed on multiunit runner and rotates under the drive of initiative runner, and the mould is embedded in the bush, and both ends are connected through front end housing and rear end housing respectively around the mould, and a plurality of water spray cooling unit encircle on the outer circumference of bush, and the distance between two adjacent water spray cooling unit is according to the wall thickness of molten iron by thick to thin crescent, waters the package and inserts in the bush.
Further, a ladle is inserted into the bushing at an axial center position.
Furthermore, the number of the multiple groups of rotating wheels is four groups of rotating wheels, and the four groups of rotating wheels are respectively arranged on the front side and the rear side of the lining.
Furthermore, each group of rotating wheels comprises a rotating wheel frame body and a wheel body, the wheel body is rotatably installed on the rotating wheel frame body, and the wheel body is in contact with the lining.
Further, each water spray cooling unit comprises a cooling water pipe, a plurality of cooling water nozzles and a cooling water switch, the cooling water pipe is surrounded on the outer side wall of the lining, the cooling water nozzles are installed on the cooling water pipe at equal intervals, and the water outlet sides of the cooling water nozzles face towards the lining.
Further, the casting device also comprises a bracket, wherein the bracket is arranged on the front side of the lining, and the casting ladle is arranged on the bracket.
Furthermore, the device also comprises a computer host, a temperature inspection system and a thermocouple, wherein the computer host, the temperature inspection system and the thermocouple are connected with the die.
The invention also provides a casting method of the ultra-large cylinder sleeve accurate water-cooling temperature-control centrifugal casting device, which comprises the following steps:
the method comprises the following steps: selecting casting and casting mold materials, reasonably setting centrifugal casting process parameters, and carrying out modeling calculation on the centrifugal casting process;
step two: a molten iron mold filling stage;
pouring molten iron into a mould of the ultra-large cylinder sleeve accurate water-cooling temperature-control centrifugal casting device, immediately rotating the molten iron with a casting mould rotating at a high speed under the action of centrifugal force, and completely pouring the molten iron into the mould according to the pre-calculated pouring time;
step three: a molten iron solidification stage;
the casting mold continues to keep rotating, the molten iron enters a solidification stage under the state, and cooling water is introduced after the molten iron is poured into the casting mold for a period of time;
step four: cooling the molten iron;
cooling water pipes and water spraying rings are distributed on the periphery of the mold, heat is transferred to the mold in a mold filling stage and a solidification stage by molten iron, then the heat is taken away by cooling water sprayed on the mold, the molten iron is gradually cooled, and the cooling water is recycled after being cooled; and designing water path arrangement and water spraying time of the water spraying ring according to the obtained temperature field distribution results of the casting and the casting mold to enable the casting to be solidified simultaneously, stopping the casting mold from rotating gradually after cooling water is turned off, cooling the casting to room temperature gradually in the air, and taking out the casting to finish the centrifugal casting of the ultra-large cylinder sleeve with accurate water cooling temperature control.
Further, the process for reasonably setting the centrifugal casting process parameters in the step one comprises the following steps: before the experiment begins, the corresponding technological parameters of the casting are simulated and calculated through a computer host, the position, the water spraying amount and the water spraying time of the water spraying ring are determined according to the simulation result, and then the molten iron is poured.
Further, the cooling process of the molten iron in the fourth step is as follows:
step four, firstly: according to the temperature field simulation result of the casting and the casting mold, opening a 1#,2#,3# circulating water switch after the molten iron is poured into the mold for a period of time, starting to introduce cooling water, and controlling the water pressure to be 0.3-0.5 MPa; according to the simulation result of the temperature field obtained by simulation, the nozzles are provided with cooling water nozzles in the whole course of the mold, small holes are uniformly arranged in each group in the axial direction of the mold, the diameter of each hole is 1, the distance from the first nozzle to the end face of the mold, the distance from the first nozzle to the nozzle and the radial distance from the first nozzle to the excircle of the large end of the mold are selected, the nozzles are aligned to the axis of the mold, and 3# circulating water is connected;
step four and step two: according to the temperature field simulation result, finding out that the temperature field distribution at the step of the mold is uneven, and the defects of thermal joints and shrinkage porosity are easily generated at the position, therefore, adding cooling water nozzles at the position, uniformly arranging the nozzles along the circumferential direction of the mold, uniformly arranging small holes in the axial direction of the mold for each group, wherein the diameter of each hole is 1, selecting the distance from a first nozzle to the end surface of the mold, the distance from the first nozzle to the end surface of the mold and the radial distance from the first nozzle to the excircle of the large end of the mold, aligning the nozzles to the axis of the mold, and connecting 1# circulating water;
step four and step three: at the front end of the mold, the heat of the casting is large, and a cooling water nozzle needs to be added and discharged to help the casting to dissipate heat so as to realize simultaneous solidification; therefore, a cooling water discharging nozzle is added at the position; small holes are uniformly arranged in each group in the axial direction of the die, and the diameter of each hole is 5; selecting the distance between a nozzle and the end face of the mold, the distance between the nozzles and the outer circle radial distance between the nozzle and the large end of the mold according to the area range of the thick large part of the casting, aligning the nozzle to the axis of the mold, and connecting 2# circulating water;
step four: and (3) keeping spraying water by circulating cooling water of No. 1, no. 2 and No. 3, stopping the cooling water until 180s when the machine is stopped, and gradually cooling the casting under the action of the cooling water to realize simultaneous solidification.
Compared with the prior art, the invention has the following effects:
1. the invention combines the numerical simulation technology, properly improves the cooling rate and the cooling time for the thick and large part of the casting which is solidified later, reduces the flow and the time of water spraying for the thin wall part and the two end positions of the casting to achieve the simultaneous solidification, reduces the defects of thermal shrinkage, shrinkage cavity, shrinkage porosity and the like of the casting, improves the mechanical property of the cylinder sleeve and meets the actual production requirement.
2. The invention starts from the cooling process of the cylinder sleeve mould, adopts different cooling water flow and cooling time for different positions of the cylinder sleeve according to the temperature field simulation result of the casting and the mould, reduces the trial and error cost to a great extent, provides an experimental scheme quickly and efficiently, has strong flexibility, is suitable for large cylinder sleeves with different sizes, can greatly reduce the production cost and improve the molding quality of the casting.
3. The invention can realize the repeated use of the circulating water sprayed from the water spray ring, the equipment is simple and easy to operate, the water spray flow and time of the water spray ring are calculated through numerical simulation, the economic benefit is improved, the data reliability is ensured, the experimental efficiency can be improved by 20%, the manpower and material resources are greatly saved, and the production cost of an enterprise is saved by 13%.
Drawings
Fig. 1 is a calculation result of a temperature field of a casting at different times, wherein (a) represents a calculation result of a temperature field when t =90 s; (b) represents the temperature field calculation result when t =120 s; (c) represents the temperature field calculation result when t =740 s; (d) represents the temperature field calculation result when t =920 s;
fig. 2 shows the results of temperature field calculations at different times of the mold, wherein (a) indicates the results of temperature field calculations at t =90 s; (b) represents the temperature field calculation result when t =120 s; (c) represents the temperature field calculation result when t =740 s; (d) represents the temperature field calculation result when t =920 s;
FIG. 3 is a schematic view of a centrifugal casting apparatus;
FIG. 4 is a side view of FIG. 3;
fig. 5 is a schematic diagram of the water path arrangement of the water spray ring, wherein 4 horizontal lines are respectively arranged from inside to outside according to the axis of the bushing: 3# recirculated cooling water route, 1# recirculated cooling water route, 2# recirculated cooling water route and 2# recirculated cooling water route, the vertical line on every water route represents the water spout, and the delivery port of water spout is apart from the distance of mould inequality in the radial direction, and is far away in the radial direction apart from the axis of bush, and its water spout is according to the near DE nozzle of using of distance, and the duckbilled of using of distance.
Detailed Description
The first specific implementation way is as follows: the embodiment is described with reference to fig. 3 to 4, and the precise water-cooling temperature-control centrifugal casting device for the ultra-large cylinder sleeve of the embodiment comprises a casting ladle 2, a base 18, a plurality of groups of rotating wheels 19, a motor 16, a rotating shaft 17, a bushing 4, a mold 5, a front end cover 3, a plurality of water-spraying cooling units and a rear end cover 12,
the multiple groups of rotating wheels 19 are divided into two rows and symmetrically installed on the base 18, the motor 16 is connected with one group of rotating wheels 19 through the rotating shaft 17, the group of rotating wheels 19 are driving rotating wheels, the bushing 4 is installed on the multiple groups of rotating wheels 19 and driven by the driving rotating wheels to rotate, the mold 5 is embedded in the bushing 4, the front end and the rear end of the mold 5 are respectively connected through the front end cover 3 and the rear end cover 12, the multiple water spray cooling units are arranged on the outer circumference of the bushing 4 in a surrounding mode, the distance between every two adjacent water spray cooling units is gradually increased from thick to thin according to the wall thickness of molten iron 7, and the casting ladle 2 is inserted into the bushing 4.
The embodiment solves the problems that the yield of the ultra-large cylinder sleeve with the cylinder diameter of 270-400 mm is low, the casting molding quality is poor, and simultaneous solidification cannot be realized. And the problems of the position arrangement of a water spraying opening, the water spraying flow and the water spraying time of the cylinder sleeve in the cooling process. The numerical simulation technology is combined, the cooling rate and the cooling time are properly improved for the thick and large part of the casting which is solidified later, the flow and the time of water spraying are reduced for the thin wall part and the two end positions of the casting, so that the simultaneous solidification is achieved, the defects of thermal shrinkage, shrinkage cavity, shrinkage porosity and the like of the casting are reduced, the mechanical property of the cylinder sleeve is improved, and the actual production requirement is met.
The second embodiment is as follows: the present embodiment will be described with reference to fig. 3, and the ladle 2 of the present embodiment is inserted into the liner 4 at the axial center position. So set up, be convenient for to water the accurate pouring ladle pour into the mould with the molten iron into, be convenient for moreover guarantee that the wall thickness of mould in centrifugal process equals and symmetrical. Other components and connections are the same as in the first embodiment.
The third concrete implementation mode: referring to fig. 3, the present embodiment is described, in which the number of the plurality of sets of runners 19 is four, and the four sets of runners 19 are respectively installed on the front and rear sides of the liner 4. So set up, be convenient for provide sufficient cooling space for a plurality of water spray cooling units, guarantee that the cooling of molten iron is more even. Other components and connection relationships are the same as in the first or second embodiment.
The fourth concrete implementation mode: referring to fig. 4 for describing the present embodiment, each set of wheels 19 of the present embodiment includes a wheel frame 19-1 and a wheel body 19-2, the wheel body 19-2 is rotatably mounted on the wheel frame 19-1, and the wheel body 19-2 is in contact with the liner 4. So set up, simple structure not only can support the bush, can also provide initiative power to the centrifugal rotation of bush. Other compositions and connection relationships are the same as in the first, second or third embodiment.
The fifth concrete implementation mode: referring to fig. 3, each water spray cooling unit of the present embodiment includes a water spray ring 8 and a plurality of cooling water nozzles 9, the water spray ring 8 surrounds the outer sidewall of the liner 4, the plurality of cooling water nozzles 9 are installed on the water spray ring 8 at equal intervals, and the water outlet side of the plurality of cooling water nozzles 9 faces the liner 4. So set up, the molten iron is poured and is accomplished the back and is sprayed water cooling to the mould outer wall by the nozzle 9 of water spray ring 8. Other compositions and connection relationships are the same as those in the first, second, third or fourth embodiment.
The sixth specific implementation mode: the present embodiment is described with reference to fig. 3, and the present embodiment further includes a holder 1, the holder 1 is attached to the front side of the liner 4, and the ladle 2 is attached to the holder 1. So set up, be convenient for provide the support to the ladle. Other compositions and connection relationships are the same as in the first, second, third, fourth or fifth embodiment.
The seventh embodiment: the embodiment is described with reference to fig. 3, and the embodiment further includes a host computer 13, a temperature inspection system 14, and a thermocouple 15, and the host computer 13, the temperature inspection system 14, and the thermocouple 15 are connected to the mold 5. So set up, accuracy when having guaranteed temperature measurement can adjust the water yield and the water spray time of water spray ring in real time, realizes accurate accuse temperature. Other compositions and connection relationships are the same as in the first, second, third, fourth, fifth or sixth embodiment.
According to the accurate water-cooling temperature-control centrifugal casting device for the ultra-large cylinder sleeve, before an experiment is started, corresponding process parameters of a casting are simulated and calculated through the computer host 12, the position of a water spraying ring, the water spraying amount and the water spraying time are determined according to a simulation result, and then molten iron is poured. When pouring, the casting ladle 2 is fixed on the bracket 1, molten iron 7 is poured into the casting ladle, the molten iron flows into the inner wall of the mould 5 along the pipeline, and the mould is always kept to rotate at a high speed under the drive of the rotating wheel 19, the rotating shaft 17 and the motor 16, so that the molten iron and the mould rotate together to carry out centrifugal motion. The mold is sleeved with a bushing 4, a front end cover 3 and a rear end cover 12 are arranged at the front and the rear of the mold, the front end cover and the rear end cover are both kept fixed by fixing bolts 11, and a rotating wheel 19 is fixed on a base 18. And after the molten iron is poured, the outer wall of the mold is sprayed with water and cooled by a nozzle 9 of a cooling water pipe 8. The infrared temperature measurement window 6 is arranged at the top of the lining 4, the lining 4 and the mould 5 can be directly observed, meanwhile, the thermocouple 15 measures the temperature of the mould in real time, and data are transmitted to the temperature polling instrument 14 and recorded in the host computer 13. Therefore, the accuracy in temperature measurement is ensured, the water quantity and the water spraying time of the water spraying ring can be adjusted in real time, and the accurate temperature control is realized.
The specific implementation mode eight: the present embodiment will be described with reference to fig. 3 and 4, and the casting method of the present embodiment includes the steps of:
the method comprises the following steps: selecting a casting and a casting material, reasonably setting centrifugal casting process parameters, and carrying out modeling calculation on the centrifugal casting process;
step two: a molten iron mold filling stage;
pouring molten iron into a mold of the ultra-large cylinder sleeve accurate water-cooling temperature-control centrifugal casting device, wherein the molten iron immediately rotates along with a casting mold rotating at a high speed under the action of centrifugal force, and all the molten iron enters the mold according to the pre-calculated pouring time;
step three: a molten iron solidification stage;
the casting mold continues to rotate, molten iron enters a solidification stage in the state, and cooling water and the like are introduced after the molten iron is poured into the mold for a period of time;
step four: cooling the molten iron;
cooling water pipes and water spraying rings are distributed on the periphery of the mold, heat of molten iron is transferred to the mold in a mold filling stage and a solidification stage, then the heat is taken away through cooling water sprayed on the mold, the molten iron is gradually cooled, and the cooling water is recycled after being cooled; according to the obtained temperature field distribution results of the casting and the casting mold, water path distribution and water spraying time of the water spraying ring are designed, so that the casting is solidified simultaneously, after cooling water is turned off, the casting mold stops rotating gradually, the casting is cooled to room temperature gradually in the air, and the casting is taken out, so that the centrifugal casting of the ultra-large cylinder sleeve with accurate water cooling temperature control is completed.
The molten iron of the present embodiment is poured into a mold of a horizontal centrifugal casting machine, and the molten iron immediately rotates along with a casting mold rotating at a high speed under the action of centrifugal force, and the molten iron is entirely poured into the mold according to the pouring time calculated in advance. The filling stage of the molten iron; the casting mold keeps rotating continuously, and molten iron enters a solidification stage under the state. In order to reduce the chilling effect of cooling water on the casting, which may generate larger internal stress to cause cold cracking and other phenomena, the cooling water and the like are introduced after the molten iron is poured into the mold for a period of time;
the specific implementation method nine: referring to fig. 3, the process of reasonably setting the centrifugal casting process parameters in the first step of the present embodiment is as follows: before the experiment begins, the corresponding technological parameters of the casting are simulated and calculated through the computer host 13, the position of the water spraying ring, the water spraying amount and the water spraying time are determined according to the simulation result, and then the molten iron is poured. So set up, it is little at 3# recirculated cooling water overall cooling effect, the whole gradual cooling of molten iron. Under the auxiliary cooling effect of the No. 1 circulating cooling water, the thin and thick connection areas of the casting are almost solidified at the same time, and the generation of heat joints is reduced. Under the enhanced cooling effect of the No. 2 circulating cooling water, the thick and large part of the casting is accelerated to solidify, and the defects of segregation, shrinkage cavity, shrinkage porosity and the like are reduced. Other compositions and connection relations are the same as those of any one of the first to eighth embodiments.
The specific implementation mode is ten: the present embodiment is described with reference to fig. 3 and 4, and the cooling process of the molten iron in step four of the present embodiment is as follows:
step four, firstly: according to the temperature field simulation result of a casting and a casting mold, after molten iron is poured into the mold for a period of time, the 1#,2#, and 3# circulating water switches are opened, the 3# circulating cooling water is closest to the outer surface of the mold, the number of the water spraying rings is the largest, the main cooling effect is achieved, the 1# circulating cooling water is arranged on the periphery of the 3# circulating cooling water, the water spraying rings are mainly distributed in the thin and thick connection area of the casting and achieve the auxiliary cooling effect, the 2# circulating cooling water is arranged on the outermost periphery, two water pipes are used for synchronously spraying water, the water spraying rings of each water pipe are different in axial distribution, and the water spraying rings are mainly distributed at the front end of the casting with large thickness and final solidification, and the reinforced cooling effect is achieved. Cooling water is introduced, and the water pressure is controlled to be 0.3-0.5 MPa; according to the simulation result of the temperature field obtained by simulation, the nozzles are provided with cooling water nozzles in the whole course of the mold, small holes are uniformly arranged in each group in the axial direction of the mold, the diameter of each hole is 1, the distance from the first nozzle to the end face of the mold, the distance from the first nozzle to the nozzle and the radial distance from the first nozzle to the excircle of the large end of the mold are selected, the nozzles are aligned to the axis of the mold, and 3# circulating water is connected;
step four: according to the temperature field simulation result, finding out that the temperature field distribution at the step of the mold is uneven, and the defects of thermal joints and shrinkage porosity are easily generated at the position, therefore, adding cooling water nozzles at the position, uniformly arranging the nozzles along the circumferential direction of the mold, uniformly arranging small holes in the axial direction of the mold for each group, wherein the diameter of each hole is 1, selecting the distance from a first nozzle to the end surface of the mold, the distance from the first nozzle to the end surface of the mold and the radial distance from the first nozzle to the excircle of the large end of the mold, aligning the nozzles to the axis of the mold, and connecting 1# circulating water;
step four and step three: at the front end of the mold, the heat of the casting is large, and a cooling water nozzle needs to be added and discharged to help the casting to dissipate heat so as to realize simultaneous solidification; therefore, a cooling water discharging nozzle is added at the position; small holes are uniformly arranged in each group in the axial direction of the die, and the diameter of each hole is 5; selecting the distance from a nozzle to the end face of the mold, the distance from the nozzle and the radial distance from the nozzle to the excircle of the large end of the mold according to the area range of the thick and large part of the casting, aligning the nozzle to the axis of the mold, and connecting No. 2 circulating water;
step four: and (3) keeping spraying water by circulating cooling water of No. 1, no. 2 and No. 3, stopping the cooling water until 180s when the machine is stopped, and gradually cooling the casting under the action of the cooling water to realize simultaneous solidification.
So set up, it is little at 3# recirculated cooling water total cooling effect, the whole gradual cooling of molten iron. Under the auxiliary cooling effect of the No. 1 circulating cooling water, the thin and thick connection areas of the casting are approximately solidified at the same time, and the generation of hot spots is reduced. Under the enhanced cooling effect of the No. 2 circulating cooling water, the thick and large part of the casting is accelerated to solidify, and the defects of segregation, shrinkage cavity, shrinkage porosity and the like are reduced. Other components and connection relationships are the same as those in any one of the first to ninth embodiments.
Example (b):
the invention adopts commercial finite element calculation simulation software to carry out coupling simulation calculation on the temperature field and flow field of the casting and the casting mould. The casting is an ultra-large cylinder sleeve with the pore diameter of 265mm and the maximum outer diameter of 390mm, and the wall thickness of the casting mould is about 2 times of that of the casting, the thinnest 50mm and the thickest 149mm. The molten iron is high-molybdenum cast iron, the casting mold is H13 steel, the casting temperature is 1430 ℃, the casting time is 90s, the centrifugal speed is 700rpm, the preheating temperature of the casting mold is 200 ℃, and the heat exchange coefficient of the casting mold is 1000W/(m) 2 K). The results of the temperature field simulation calculations for the casting and the mold at different times are shown in fig. 1 and 2.
According to the temperature fields of the castings and the casting molds shown in fig. 1 and 2, the temperature field distribution is uneven at the thick parts and the steps of the castings. Therefore, the number of cooling water nozzles is increased appropriately at these portions, and the water spraying time is prolonged. According to the parameters adopted by the simulation, the centrifugal casting equipment shown in figures 3 and 4 is used for production, a water spraying ring accurate temperature control device is added in the centrifugal casting equipment, and the water path arrangement is shown in figure 5.
And pouring molten iron into a mold of a horizontal centrifugal casting machine, wherein the molten iron immediately rotates along with the casting mold rotating at a high speed under the action of centrifugal force, the pouring time is 90 seconds, and all the molten iron enters the mold. This is the molten iron mold filling stage. The casting mold continues to keep rotating, and the molten iron enters a solidification stage under the state. From the results of the temperature field simulation of the casting and the mold, it can be seen that, immediately after the mold filling is completed, i.e., t =90s, the mold is not cooled yet, and the temperature fields of the casting and the mold are uniformly distributed, as shown in fig. 1 (a) and 2 (a). In order to reduce chilling action of cooling water on the casting, which may generate larger internal stress to cause cold cracking and other phenomena, the cooling water and the like are introduced 30 seconds after the molten iron is poured into the mold.
And opening 1#,2#,3# circulating water switches 30 seconds after the molten iron is poured into the mold, starting to introduce cooling water, and controlling the water pressure to be 0.3-0.5 MPa. According to the figures 1 (b) and 2 (b), 3 groups of cooling water nozzles are arranged in the whole die, 5 holes are uniformly arranged in each group in the axial direction of the die, the diameter of each hole is 1, the distance from a first nozzle to the end face of the die is 120mm +/-10 mm, the distance between the nozzles is 140mm, the radial distance from the first nozzle to the outer circle of the large end of the die is 150 +/-20 mm, the nozzles are aligned to the axis of the die, and 3# circulating water is connected. According to the graphs 1 (c) and 2 (c), the temperature field distribution at the mould step is not uniform, and the defects such as thermal junctions, shrinkage cavities and the like are easily generated at the position, so that the cooling water nozzles are added at the position, 3 groups are uniformly arranged along the circumferential direction of the mould, 3 holes are uniformly arranged in the axial direction of the mould in each group, the diameter of each hole is 1, the distance from the first nozzle to the end face of the mould is 120mm +/-10 mm, the distance between the nozzles is 140mm, the radial distance from the excircle of the large end of the mould is 150 +/-20 mm, the nozzles are aligned to the axle center of the mould, and the 1# circulating water is connected. According to fig. 1 (d) and 2 (d), the heat of the casting at the large end of the mold is large, and a cooling water nozzle needs to be added and discharged to help the heat dissipation of the casting so as to realize simultaneous solidification. Thus, 10 groups of cooling water nozzles are added at this location. Each group is provided with 2 holes uniformly arranged in the axial direction of the die, and the diameter of each hole is 5. Wherein 7 first nozzles of group are 120mm 10mm apart from the distance of mould terminal surface, and 3 first nozzles of group are 70mm 10mm apart from the distance of mould terminal surface in addition, and the nozzle interval is 120mm, apart from mould main aspects excircle radial distance 150 20mm, and the mould axle center is aimed at to the nozzle, connects 2# circulating water. And (4) keeping the water spraying time of the circulating cooling water of 1#,2#, and 3# for 620 seconds, stopping the cooling water until 180 seconds when the machine is stopped, and gradually cooling the casting under the action of the cooling water to realize nearly simultaneous solidification. And after the cooling water is closed, the casting mold stops rotating gradually, the casting is cooled to room temperature gradually in the air, and the casting is taken out.
Through infrared temperature measurement window and temperature patrol and examine the appearance, can carry out real-time detection to the temperature, also can adjust the size and the water spray time of water spray volume in time. Therefore, the casting is ensured to be solidified almost simultaneously, the occurrence of thermal junctions and shrinkage cavities and shrinkage porosity is greatly reduced, and the mechanical property of the casting is improved.
Although the invention has been described with respect to a preferred embodiment, it will be understood by those skilled in the art that the foregoing and other changes, omissions and deviations in the form and detail thereof may be made without departing from the scope of this invention.
Claims (10)
1. The utility model provides an accurate water-cooling accuse temperature centrifugal casting device of super-large cylinder liner, it is including watering package (2), its characterized in that: it also comprises a base (18), a plurality of groups of rotating wheels (19), a motor (16), a rotating shaft (17), a bushing (4), a mould (5), a front end cover (3), a plurality of water spray cooling units and a rear end cover (12),
the multi-group runner (19) is divided into two rows and symmetrically installed on the base (18), the motor (16) is connected with one group of runner (19) through the rotating shaft (15), the group of runners (19) is a driving runner, the bushing (4) is installed on the multi-group runner (19) and driven by the driving runner to rotate, the mold (5) is embedded in the bushing (4), the front end and the rear end of the mold (5) are connected with the rear end cover (12) through the front end cover (3) respectively, the multiple water spray cooling units are wound on the outer circumference of the bushing (4), the distance between every two adjacent water spray units is gradually increased from thickness to thickness according to the wall thickness of molten iron (7), and the casting ladle (2) is inserted into the bushing (4).
2. The accurate water-cooling accuse temperature centrifugal casting device of ultra-large cylinder liner according to claim 1, characterized in that: the ladle (2) is inserted into the bushing (4) at the center of the axis.
3. The accurate water-cooling temperature-control centrifugal casting device for the ultra-large cylinder sleeve according to claim 1 or 2, characterized in that: the number of the groups of rotating wheels (19) is four groups of rotating wheels (19), and the four groups of rotating wheels (19) are respectively arranged on the front side and the rear side of the lining (4).
4. The accurate water-cooling accuse temperature centrifugal casting device of super-large cylinder liner according to claim 3, characterized in that: each group of rotating wheels (19) comprises a rotating wheel frame body (19-1) and a wheel body (19-2), the wheel body (19-2) is rotatably arranged on the rotating wheel frame body (19-1), and the wheel body (19-2) is in contact with the lining (4).
5. The accurate water-cooling temperature-control centrifugal casting device for the ultra-large cylinder sleeve according to claim 1 or 4, characterized in that: every water spray cooling unit all includes condenser tube (8), a plurality of cooling water nozzle (9) and cooling water switch (10), and condenser tube (8) distribute on bush (4) lateral wall, and a plurality of cooling water nozzle (9) are equidistant to be installed on condenser tube (8), and the play water side of a plurality of cooling water nozzle (9) is towards bush (4).
6. The accurate water-cooling accuse temperature centrifugal casting device of super-large cylinder liner according to claim 5, characterized in that: the casting ladle is characterized by further comprising a support (1), wherein the support (1) is installed on the front side of the lining (4), and the casting ladle (2) is installed on the support (1).
7. The accurate water-cooling accuse temperature centrifugal casting device of ultra-large cylinder liner according to claim 6, characterized in that: the temperature monitoring device further comprises a host computer (13), a temperature monitoring system (14) and a thermocouple (15), wherein the host computer (13), the temperature monitoring system (14) and the thermocouple (15) are connected with the mold (5).
8. A casting method of the ultra-large cylinder sleeve accurate water-cooling temperature-control centrifugal casting device which adopts any one of claims 1 to 7 is characterized in that: it comprises the following steps:
the method comprises the following steps: selecting a casting and a casting material, reasonably setting centrifugal casting process parameters, and carrying out modeling calculation on the centrifugal casting process;
step two: a molten iron mold filling stage;
pouring molten iron into a mould of the ultra-large cylinder sleeve accurate water-cooling temperature-control centrifugal casting device, immediately rotating the molten iron with a casting mould rotating at a high speed under the action of centrifugal force, and completely pouring the molten iron into the mould according to the pre-calculated pouring time;
step three: a step of solidifying molten iron;
the casting mold continues to keep rotating, the molten iron enters a solidification stage under the state, and cooling water is introduced after the molten iron is poured into the casting mold for a period of time;
step four: cooling molten iron;
cooling water pipes and water spraying rings are distributed on the periphery of the mold, heat of molten iron is transferred to the mold in a mold filling stage and a solidification stage, then the heat is taken away through cooling water sprayed on the mold, the molten iron is gradually cooled, and the cooling water is recycled after being cooled; according to the obtained temperature field distribution results of the casting and the casting mold, water path distribution and water spraying time of the water spraying ring are designed, so that the casting is solidified simultaneously, after cooling water is turned off, the casting mold stops rotating gradually, the casting is cooled to room temperature gradually in the air, and the casting is taken out, so that the centrifugal casting of the ultra-large cylinder sleeve with accurate water cooling temperature control is completed.
9. The casting method according to claim 8, wherein: the process for reasonably setting the centrifugal casting process parameters in the first step comprises the following steps: before the experiment begins, the corresponding technological parameters of the casting are simulated and calculated through the computer host (13), the position of the water spraying ring, the water spraying amount and the water spraying time are determined according to the simulation result, and then the molten iron is poured.
10. The casting method as recited in claim 9, wherein: the cooling process of the molten iron in the fourth step is as follows:
step four, firstly: according to the simulation result of the temperature field of the casting and the casting mold, opening 1#,2#,3# circulating water switches after the molten iron is poured into the mold for a period of time, starting to introduce cooling water, and controlling the water pressure to be 0.3-0.5 MPa; according to the simulation result of the temperature field obtained by simulation, cooling water nozzles are arranged in the nozzles in the whole process of the mold, small holes are uniformly arranged in each group in the axial direction of the mold, the diameter of each hole is 1, the distance from a first nozzle to the end face of the mold, the distance from the first nozzle to the nozzle and the radial distance from the first nozzle to the outer circle of the large end of the mold are selected, the nozzles are aligned to the axis of the mold, and the nozzles are connected with No. 3 circulating water;
step four: according to the temperature field simulation result, finding out the defects that the temperature field distribution at the step of the die is not uniform, and the thermal budget and shrinkage porosity are easily generated at the position, therefore, adding and discharging cooling water nozzles at the position, uniformly arranging the cooling water nozzles along the circumferential direction of the die, uniformly arranging small holes in each group in the axial direction of the die, wherein the diameter of each hole is 1, selecting the distance from a first nozzle to the end face of the die, the distance from the first nozzle to the end face of the die and the radial distance from the first nozzle to the excircle of the large end of the die, aligning the nozzles to the axis of the die, and connecting 1# circulating water;
step four and step three: at the front end of the mold, the heat of the casting is large, and a cooling water nozzle needs to be added and discharged to help the casting to dissipate heat so as to realize simultaneous solidification; therefore, a cooling water nozzle is added at the position; small holes are uniformly arranged in each group in the axial direction of the die, and the diameter of each hole is 5; selecting the distance between a nozzle and the end face of the mold, the distance between the nozzles and the outer circle radial distance between the nozzle and the large end of the mold according to the area range of the thick large part of the casting, aligning the nozzle to the axis of the mold, and connecting 2# circulating water;
step four: and (4) keeping spraying water for the circulating cooling water of 1#,2#, and 3#, stopping the cooling water until 180s when the machine is stopped, and gradually cooling the casting under the action of the cooling water to realize simultaneous solidification.
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