CN113172213B - Casting method of centrifugal composite roller - Google Patents
Casting method of centrifugal composite roller Download PDFInfo
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- CN113172213B CN113172213B CN202110383329.0A CN202110383329A CN113172213B CN 113172213 B CN113172213 B CN 113172213B CN 202110383329 A CN202110383329 A CN 202110383329A CN 113172213 B CN113172213 B CN 113172213B
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- 238000005266 casting Methods 0.000 title claims abstract description 60
- 238000000034 method Methods 0.000 title claims abstract description 32
- 239000002131 composite material Substances 0.000 title claims abstract description 20
- 229910052751 metal Inorganic materials 0.000 claims abstract description 46
- 239000002184 metal Substances 0.000 claims abstract description 45
- 238000001816 cooling Methods 0.000 claims abstract description 14
- 238000010438 heat treatment Methods 0.000 claims abstract description 10
- 239000000203 mixture Substances 0.000 claims abstract description 10
- 239000007788 liquid Substances 0.000 claims abstract description 8
- 244000035744 Hura crepitans Species 0.000 claims abstract description 7
- 230000005484 gravity Effects 0.000 claims abstract description 7
- 239000010410 layer Substances 0.000 claims description 123
- 239000011162 core material Substances 0.000 claims description 59
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 14
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 12
- 150000002910 rare earth metals Chemical class 0.000 claims description 12
- 239000012535 impurity Substances 0.000 claims description 10
- 239000002054 inoculum Substances 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 10
- 239000011777 magnesium Substances 0.000 claims description 7
- 230000008569 process Effects 0.000 claims description 7
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 5
- 229910052749 magnesium Inorganic materials 0.000 claims description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 4
- 229910052742 iron Inorganic materials 0.000 claims description 4
- 229910001245 Sb alloy Inorganic materials 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- 229910052804 chromium Inorganic materials 0.000 claims description 3
- 239000011229 interlayer Substances 0.000 claims description 3
- 229910052750 molybdenum Inorganic materials 0.000 claims description 3
- 229910052759 nickel Inorganic materials 0.000 claims description 3
- IBDBQEKFAWOMAQ-UHFFFAOYSA-N [Mn].[Cu].[Sb] Chemical compound [Mn].[Cu].[Sb] IBDBQEKFAWOMAQ-UHFFFAOYSA-N 0.000 claims description 2
- 239000002140 antimony alloy Substances 0.000 claims description 2
- 239000012774 insulation material Substances 0.000 claims 1
- 238000004321 preservation Methods 0.000 claims 1
- 238000007711 solidification Methods 0.000 abstract description 6
- 230000008023 solidification Effects 0.000 abstract description 6
- 239000011572 manganese Substances 0.000 description 8
- 239000000306 component Substances 0.000 description 6
- 230000004927 fusion Effects 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 238000004364 calculation method Methods 0.000 description 4
- 229910002804 graphite Inorganic materials 0.000 description 4
- 239000010439 graphite Substances 0.000 description 4
- 238000011081 inoculation Methods 0.000 description 3
- 229910052748 manganese Inorganic materials 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- 239000010955 niobium Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 2
- 229910001567 cementite Inorganic materials 0.000 description 2
- 238000009750 centrifugal casting Methods 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
- 239000010949 copper Substances 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- KSOKAHYVTMZFBJ-UHFFFAOYSA-N iron;methane Chemical compound C.[Fe].[Fe].[Fe] KSOKAHYVTMZFBJ-UHFFFAOYSA-N 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- 229910052758 niobium Inorganic materials 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 229910000997 High-speed steel Inorganic materials 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 229910052787 antimony Inorganic materials 0.000 description 1
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 1
- FAWGZAFXDJGWBB-UHFFFAOYSA-N antimony(3+) Chemical compound [Sb+3] FAWGZAFXDJGWBB-UHFFFAOYSA-N 0.000 description 1
- 230000003749 cleanliness Effects 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
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- 230000000694 effects Effects 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 1
- 230000006911 nucleation Effects 0.000 description 1
- 238000010899 nucleation Methods 0.000 description 1
- 229910001562 pearlite Inorganic materials 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
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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
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/16—Casting in, on, or around objects which form part of the product for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/46—Ferrous alloys, e.g. steel alloys containing chromium with nickel with vanadium
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/48—Ferrous alloys, e.g. steel alloys containing chromium with nickel with niobium or tantalum
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/20—Recycling
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
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- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Reduction Rolling/Reduction Stand/Operation Of Reduction Machine (AREA)
Abstract
The invention provides a casting method of a centrifugal composite roller, which comprises the following casting process steps: step one, heating the temperature of the outer layer molten metal to a pouring temperature T1Then, injecting the mixture into a casting mold rotating at a high speed; step two, after the outer layer is poured, the temperature of the inner surface of the outer layer is reduced to N1Then, pouring the middle layer; step three, after the pouring of the intermediate layer is finished, the temperature of the inner surface of the intermediate layer is reduced to N2Then, the centrifugal rotary die is detached from the centrifugal machine and assembled with a tool for gravity casting of the core part, so that core part pouring is carried out; and step four, after the core is poured, arranging a sealed heat-insulating cover outside the sand box, cooling for 10 hours, removing the heat-insulating cover, and dismantling the box after natural cooling. The method guides the solidification sequence of the core part by reasonably controlling the temperature of the poured metal liquid and the temperature of the contact layer and adopting the non-uniform wall thickness arrangement with the large upper end and the small lower end for the roller intermediate layer, thereby reducing the shrinkage porosity and the shrinkage cavity at the roller body of the roller by more than 44.1 percent.
Description
Technical Field
The invention relates to the field of roller manufacturing, in particular to a casting method of a centrifugal composite roller.
Background
The rolls are the core components of a rolling mill. The centrifugal composite casting method for various metals is one of the roller manufacturing methods which are widely applied at present. Because the section of the roller is large, and the cooling speed and the cooling sequence of the roller body and the roller neck are difficult to control, the problem of central shrinkage of a roller core part is often caused, and the mechanical property and the accident resistance of the roller are reduced. In addition, due to the fact that multiple metals are subjected to composite pouring, the bonding surfaces between different metals are not well fused, the problems that cracks and even peeling of the outer layer occur and the like can be caused, and the service life of the roller is greatly shortened. Therefore, research and development of the improved roller manufacturing process, reduction of the central shrinkage cavity of the core part and improvement of the fusion quality of the joint surface are important measures for improving the quality of the roller.
The invention discloses a centrifugal composite roller manufacturing method in CN102615108B, which discloses chemical components of roller materials, manufacturing steps and a centrifuge rotating speed control formula, and can manufacture a high-speed steel composite roller with high comprehensive quality. However, due to the limited technical conditions, the problems of poor fusion of the different metal joining surfaces and the cooling and solidification sequence of the roll core are not considered sufficiently, and the roll is likely to cause a central shrinkage problem, poor fusion of the joining surfaces, and the like.
Disclosure of Invention
In order to solve the defects in the prior art, the invention provides a casting method of a centrifugal composite roller, which can realize sequential solidification of a roller core part from bottom to top and improve the fusion quality of different metal joint surfaces, thereby solving the problems of central shrinkage of the roller and poor fusion of the joint surfaces and obtaining the high-quality roller.
The centrifugal casting method is used for casting the outer layer and the middle layer of the roller, the gravity casting method is used for casting the core part, uneven wall thickness setting with large upper end and small lower end is carried out on the middle layer when the centrifugal casting is carried out on the middle layer, and on the basis, the temperature of metal liquid of each layer and the setting of the temperature value of the inner surface after pouring are increased during pouring. The types and the contents of the metal contents of the outer layer, the middle layer and the core part of the roller are accurately proportioned, and the roller is added with an inoculant for inoculation and rare earth and metal elements.
Specifically, the invention provides a casting method of a centrifugal composite roller, which comprises the following casting process steps:
step one, heating the temperature of the outer layer molten metal to a pouring temperature T1Then, injecting the mixture into a casting mold rotating at a high speed, and adding 0.5-1.3 kg/T SiCaMn inoculant and 1.2-1.6 kg/T rare earth, wherein T is1＝L1+100℃，L1Is the outer layer liquidus of metal;
step two, after the outer layer is poured, the temperature of the inner surface of the outer layer is reduced to N1Thereafter, the casting of the intermediate layer is started, wherein N1＝S1-K1×100℃，K1＝H2/H1，H1Initial wall thickness of the outer layer, H2Effective wall thickness of the outer layer, S1The outer layer metal solidus line is adopted, the initial wall thickness of the outer layer is the initial wall thickness of the outer layer after the outer layer is poured, and after the middle layer is poured, the effective wall thickness of the outer layer is the part obtained by subtracting the fused wall thickness of the middle layer from the initial wall thickness of the outer layer;
the concrete process of pouring the intermediate layer comprises the following steps: heating the molten metal in the intermediate layer to a casting temperature T2Then, injecting the mixture into a casting mold rotating at a high speed, and adding 0.5-1.3 kg/T SiCaMn inoculant and 0.5-0.7 kg/T aluminum cake, wherein T is2＝Max(L1，L2)+K1×(Max(S1，S2)-N1)，L2Is the liquidus of the intermediate layer metal, S2The method is characterized in that the method is a middle layer metal solidus line, when the middle layer is poured, the middle layer is required to be poured into a non-uniform wall thickness, wherein the wall thickness of one end, close to an upper roll neck, of the middle layer is larger than that of one end, close to a lower roll neck, of the middle layer;
step three, after the pouring of the intermediate layer is finished, the temperature of the inner surface of the intermediate layer is reduced to N2And then, detaching the centrifugal rotary die from the centrifugal machine, and assembling the centrifugal rotary die with a tool for gravity casting of a core part for core part pouring, wherein N is2＝S2-K1×100℃；
The concrete process of core pouring is as follows: heating the core metal liquid to the casting temperature T3Then, injecting the mixture into a core casting mold, and adding 8-10 kg/t of rare earth magnesium nodulizer and6-8 kg/T of Cu-Mn-Sb alloy, wherein T3＝Max(L2，L3)+K2×(Max(S2，S3)-N2)，L3Is the liquidus of the core metal, S3Is the core solidus of the metal, K2＝G3/G2，G2Pouring weight for intermediate layer, G3Casting a weight for the core;
and step four, after the core is poured, arranging a sealed heat-insulating cover outside the sand box, removing the heat-insulating cover after cooling for 10 hours, and disassembling the sand box after natural cooling, wherein the core is guided to be sequentially solidified by the aid of a structure with the thickness of the upper end of the middle layer larger than that of the lower end of the middle layer in the process of cooling the core, and the lower part of the core is firstly cooled and the upper part of the core is secondly cooled.
Preferably, the roll outer layer material comprises the following components in percentage by weight: 2.50-3.20% of C, 0.70-0.95% of Si, 0.85-1.25% of Mn, 1.25-1.50% of Ni, 1.50-2.50% of Cr, 0.25-0.45% of Mo, 2.00-3.00% of V, 0.75-2.00% of Nb, 0.25-0.38% of W, less than or equal to 0.02% of S, less than or equal to 0.05% of P, and the balance of Fe and other impurities.
Preferably, the roll interlayer material comprises the following components in percentage by weight: 2.10-2.40% of C, 2.20-2.80% of Si, 0.35-1.25% of Mn, less than or equal to 0.02% of S, less than or equal to 0.10% of P, less than 0.10% of Ni, Cr and Mo, and the balance of Fe and other impurities.
Preferably, the roll core material comprises the following components in percentage by weight: 3.00-3.30% of C, 2.10-2.40% of Si, 0.20-0.40% of Mn, 0.20-0.40% of Ni, less than or equal to 0.10% of P, less than or equal to 0.03% of S, less than or equal to 0.15% of Cr, greater than or equal to 0.04% of Mg, and the balance of iron and other impurities.
Preferably, the heat-insulating cover is made of a heat-insulating material.
Preferably, the wall thickness of the upper end of the middle layer is 1.5-3 times of the wall thickness of the lower end of the middle layer.
Compared with the prior art, the invention has the following effects:
(1) the invention provides a casting method of a centrifugal composite roller, which guides the solidification sequence of a core part by reasonably controlling the temperature of a pouring metal liquid and the temperature of a contact layer and adopting the non-uniform wall thickness arrangement with a large upper end and a small lower end for a roller middle layer, thereby reducing shrinkage porosity and shrinkage cavity generation at the roller body of the roller by more than 44.1 percent, solving the problems of shrinkage cavity at the center of the roller and poor fusion of a joint surface and obtaining the high-quality roller.
(2) According to the casting method of the centrifugal composite roller, the rare earth and the SiCaMn inoculant are added when the outer layer is poured, and the SiCaMn inoculant and the Al element are added when the middle layer is poured, so that the discontinuity of a carbide network is promoted, and the toughness between the junction surfaces of the outer layer and the middle layer is increased. When the core is cast, rare earth magnesium nodulizer and copper, manganese and antimony elements are added, fine graphite with higher nodulizing degree can be obtained, the cementite proportion is reduced, and the tissue brittleness is reduced, so that the toughness and the strength of the joint surface of the core and the interlayer are further increased.
Drawings
FIG. 1 is a schematic flow chart of the present invention;
FIG. 2 is a schematic view of the roll casting tooling of the present invention;
FIG. 3a is a plot of the bulk of a roll body of a cast roll as it is cast using a Procast software simulation of a prior art casting method;
FIG. 3b is a plot of the bulk of the barrel of a casting roll produced using the casting method of the present invention using Procast software.
In the drawings, some of the reference numerals are as follows:
1-feeding a sand core; 2-a riser box; 3-upper end cover; 4-covering sand on the upper end; 5-rolling a mould; 6-outer layer; 7-an intermediate layer; 8-a core; 9-setting a sand core; 10-upper section of the bottom box; 11-lower section of the bottom box.
Detailed Description
Hereinafter, embodiments of the present invention will be described with reference to the drawings.
The invention aims to provide a casting method of a centrifugal composite roller, which reduces shrinkage porosity and shrinkage cavity generation or moves up to a riser by setting the pouring temperature of molten metal and the temperature of each contact layer and setting the uneven wall thickness of the upper part and the lower part of an intermediate layer, and enhances the toughness and the strength of a roller joint surface by accurately controlling the metal content and the type of each layer of the roller and adding elements such as inoculant, rare earth and the like for treatment.
The invention provides a casting method of a centrifugal composite roller, as shown in figure 1, the casting process comprises the following steps:
step one, heating the temperature of the outer layer molten metal to a pouring temperature T1Then, injecting the mixture into a casting mold rotating at a high speed, and adding 0.5-1.3 kg/T SiCaMn inoculant and 1.2-1.6 kg/T rare earth, wherein T is1＝L1+100℃，L1The outer layer liquidus.
Step two, after the outer layer is poured, the temperature of the inner surface of the outer layer is reduced to N1Thereafter, the casting of the intermediate layer is started, wherein N1＝S1-K1×100℃，K1＝H2/H1，H1Initial wall thickness of the outer layer, H2Effective wall thickness of the outer layer, S1The outer layer metal solidus line is the initial wall thickness of the outer layer after the outer layer is poured, and the outer layer effective wall thickness is the portion of the wall thickness obtained by subtracting the fused portion of the middle layer and the outer layer from the initial wall thickness of the outer layer after the middle layer is poured.
The concrete process of pouring the intermediate layer comprises the following steps: heating the molten metal in the intermediate layer to a casting temperature T2Then, injecting the mixture into a casting mold rotating at a high speed, and adding 0.5-1.3 kg/T SiCaMn inoculant and 0.5-0.7 kg/T aluminum cake, wherein T is2＝Max(L1，L2)+K1×(Max(S1，S2)-N1)，L2Is the liquidus of the intermediate layer metal, S2And (3) casting the intermediate layer to form a non-uniform wall thickness when the intermediate layer is cast, wherein the wall thickness of the intermediate layer at one end close to the upper roll neck is larger than that of the intermediate layer at one end close to the lower roll neck.
Step three, after the pouring of the intermediate layer is finished, the temperature of the inner surface of the intermediate layer is reduced to N2And then, detaching the centrifugal rotary die from the centrifugal machine, and assembling the centrifugal rotary die with a tool for gravity casting of a core part for core part pouring, wherein N is2＝S2-K1×100℃。
The concrete process of core pouring is as follows: heating the core metal liquid to the casting temperature T3Then, injecting the mixture into a core casting mold, and adding 8-10 kg/T of rare earth magnesium nodulizer and 6-8 kg/T of copper-manganese-antimony alloy, wherein T is3＝Max(L2，L3)+K2×(Max(S2，S3)-N2)，L3Is the liquidus of the core metal, S3Is the core solidus of the metal, K2＝G3/G2，G2Pouring weight for intermediate layer, G3A weight is poured for the core.
And step four, after the core is poured, arranging a sealed heat-insulating cover outside the sand box, cooling for 10 hours, removing the heat-insulating cover, and dismantling the sand box after natural cooling.
In order to make the aforementioned objects, features and advantages of the present invention more comprehensible, the present invention is described in detail with reference to fig. 2 and the following detailed description, and in order to enhance the feasibility of the present invention, a Procast software is used for simulation, which is further detailed with reference to fig. 3a and 3 b.
Fig. 2 is a schematic diagram of the roll casting tool of the present invention, which includes an upper sand core 1, a lower sand core 9, a roll mold 5 and a bottom box, wherein a dead head box 2 is arranged outside the upper sand core 1, an upper end cover 3 and upper end cover sand 4 are arranged between the upper sand core 1 and the roll mold 5, and an outer layer 6, an intermediate layer 7 and a core 8 are arranged inside the roll mold 5. The bottom box comprises a bottom box upper section 10 and a bottom box lower section 11.
In this embodiment, the specific working steps are as follows:
in the first step, the outer layer 6 of the roll is centrifugally cast from a material consisting of, by weight, C2.85%, Si 0.825%, Mn 1.05%, Ni 1.375%, Cr 2%, Mo 0.35%, V2.5%, Nb 1.375%, W0.315%, S0.008%, P0.03%, and the balance iron and other unavoidable impurities. According to a calculation formula, Procast software can be input into the embodiment for calculation according to the chemical components of the materials, and the liquidus of the outer layer metal is 1281 ℃, and the solidus of the outer layer metal is 1073 ℃. The casting temperature of molten metal on the outer layer of the roller is set to 1381 ℃.
In the examples, inoculation of the outer layer with sicann promotes discontinuity of the carbide network and results in increased impact toughness at the bond interface. After the rare earth is added, the continuity of carbide grids is eliminated, crystal grains are refined, and aggregated chrysanthemum-shaped carbide is changed into high-hardness carbide which is dispersed and distributed. The vanadium, niobium and tungsten can improve the wear resistance and red hardness.
Secondly, the intermediate layer 7 of the roller is centrifugally cast, and the intermediate layer comprises 2.25 wt% of C, 2.5 wt% of Si, 0.8 wt% of Mn, S0.0.008 wt% of P, 0.03 wt% of Ni, 0.05 wt% of Cr, 0.05 wt% of Mo, and the balance of Fe and other unavoidable impurities. Calculating the liquidus and solidus of the intermediate layer metal to 1290 ℃ and 1102 ℃ according to the chemical components of the materials and a calculation formula. Set for outer initial thickness to be 50mm, effective thickness is 40mm, then when the inner skin temperature drops to 993 ℃, pour to the intermediate level again, set up intermediate level molten metal pouring temperature 1377 ℃, and set up inhomogeneous wall thickness to the intermediate level pouring, big end wall thickness is located the upper end, and little end wall thickness is located the lower extreme, and the wall thickness of big end is about 2 times of little end to the solidification order of guide core.
The use of SiCaMn for the intermediate layer inoculation promotes discontinuity of the carbide network and results in an increase in the impact toughness of the bond interface. The addition of the aluminum element can promote the middle layer to be better fused with the outer layer and the core part and improve the toughness of the joint surface.
Thirdly, adopting a gravity casting mode for the core part 8 of the roller, setting the core part materials to comprise, by weight, 3.15% of C, 2.25% of Si, 0.3% of Mn, 0.3% of Ni, 0.05% of P, 0.008% of S, 0.1% of Cr0.05% of Mg0.05 and the balance of Fe and other inevitable impurities, and calculating the liquidus line of the core part metal to be 1210 ℃, the solidus line to be 1075 ℃, the middle layer pouring weight to be 10t and the core part pouring weight to be 12t according to a calculation formula. Setting the casting temperature of the core metal liquid as 1386 ℃ when the temperature of the inner surface layer of the middle layer is reduced to 1022 ℃, injecting the core metal liquid into a casting mold under the action of gravity, and guiding the sequential solidification of the lower part of the core part, which is firstly cooled, and the upper part of the core part, which is then cooled, by the gradient arrangement of the wall thickness of the middle layer, which is big at the top and small at the bottom.
The rare earth magnesium nodulizer added in the core can effectively remove impurity elements in molten iron, and the material cleanliness is improved. The addition of copper and manganese can make the matrix of the structure mainly be pearlite, thus reducing the proportion of cementite, reducing the brittleness of the structure and increasing the toughness and strength of the joint surface. The added antimony element can be adsorbed on the surface of the graphite and forms a layer of film, and the film has certain influence on nucleation and growth of the nodular graphite, so that fine graphite with higher spheroidization degree can be obtained, and the toughness of a joint surface can be further improved.
And step four, after the core is poured, arranging a sealed heat-insulating cover outside the sand box, cooling for 10 hours, removing the heat-insulating cover, and dismantling the box after natural cooling.
And (3) simulating the shrinkage porosity and the shrinkage cavity volume of 34cc of the roll body of the cast roll in the existing casting process by using Procast software. According to the method, the simulated shrinkage porosity and shrinkage cavity volume of the roller body is 19cc, and the shrinkage porosity and shrinkage cavity generation of the roller body are reduced by 44.1%.
The above-mentioned embodiments are merely illustrative of the preferred embodiments of the present invention, and do not limit the scope of the present invention, and various modifications and improvements made to the technical solution of the present invention by those skilled in the art without departing from the spirit of the present invention shall fall within the protection scope defined by the claims of the present invention.
Claims (6)
1. A casting method of a centrifugal composite roller is characterized in that: the casting process comprises the following steps:
step one, heating the temperature of the outer layer molten metal to a pouring temperature T1Then, injecting the mixture into a casting mold rotating at a high speed, and adding 0.5-1.3 kg/T SiCaMn inoculant and 1.2-1.6 kg/T rare earth, wherein T is1=L1+100℃，L1Is the outer layer metal liquidus;
step two, after the outer layer is poured, the temperature of the inner surface of the outer layer is reduced to N1Thereafter, the casting of the intermediate layer is started, wherein N1=S1-K1×100℃，K1=H2/H1，H1The initial wall thickness of the outer layer is,H2effective wall thickness of the outer layer, S1The outer layer metal solidus line is adopted, the initial wall thickness of the outer layer is the initial wall thickness of the outer layer after the outer layer is poured, and after the middle layer is poured, the effective wall thickness of the outer layer is the part obtained by subtracting the fused wall thickness of the middle layer from the initial wall thickness of the outer layer;
the concrete process of pouring the intermediate layer comprises the following steps: heating the molten metal in the intermediate layer to a casting temperature T2Then, injecting the mixture into a casting mold rotating at a high speed, and adding 0.5-1.3 kg/T SiCaMn inoculant and 0.5-0.7 kg/T aluminum cake, wherein T is2=Max(L1，L2) + K1×(Max(S1，S2)-N1)，L2Is the liquidus of the intermediate layer metal, S2For the middle layer metal solidus line, when the middle layer is poured, the middle layer is required to be poured into non-uniform wall thickness, wherein the wall thickness of the middle layer close to one end of the upper roll neck is larger than that of the middle layer close to one end of the lower roll neck;
step three, after the pouring of the intermediate layer is finished, the temperature of the inner surface of the intermediate layer is reduced to N2And then, detaching the centrifugal rotary die from the centrifugal machine, and assembling the centrifugal rotary die with a tool for core gravity casting to perform core pouring, wherein N is2=S2-K1×100℃；
The concrete process of core pouring is as follows: heating the core metal liquid to the casting temperature T3Then, injecting the mixture into a core casting mold, and adding 8-10 kg/T of rare earth magnesium nodulizer and 6-8 kg/T of copper-manganese-antimony alloy, wherein T is3=Max(L2，L3) + K2×(Max(S2，S3)-N2)，L3Is the liquidus of the core metal, S3Is the core solidus of the metal, K2=G3/G2，G2Pouring weight for intermediate layer, G3Casting a weight for the core;
and step four, after the core is poured, arranging a sealed heat-insulating cover outside the sand box, cooling for 10-12 hours, removing the heat-insulating cover, naturally cooling, and then disassembling the box, wherein the core is guided to be sequentially solidified by the lower part of the core which is firstly cooled and the upper part of the core which is secondly cooled by virtue of a structure with the thickness of the upper end of the middle layer larger than that of the lower end of the middle layer.
2. The method of casting a centrifugal composite roll as claimed in claim 1, wherein: the roll outer layer material comprises the following components in percentage by weight: 2.50-3.20% of C, 0.70-0.95% of Si, 0.85-1.25% of Mn, 1.25-1.50% of Ni, 1.50-2.50% of Cr, 0.25-0.45% of Mo, 2.00-3.00% of V, 0.75-2.00% of Nb, 0.25-0.38% of W, less than or equal to 0.02% of S, less than or equal to 0.05% of P, and the balance of Fe and other impurities.
3. The method of casting a centrifugal composite roll as claimed in claim 1, wherein: the roll interlayer material comprises the following components in percentage by weight: 2.10-2.40% of C, 2.20-2.80% of Si, 0.35-1.25% of Mn, less than or equal to 0.02% of S, less than or equal to 0.10% of P, less than 0.10% of Ni, Cr and Mo, and the balance of Fe and other impurities.
4. The method of casting a centrifugal composite roll as claimed in claim 1, wherein: the roll core material comprises the following components in percentage by weight: 3.00-3.30% of C, 2.10-2.40% of Si, 0.20-0.40% of Mn, 0.20-0.40% of Ni, less than or equal to 0.10% of P, less than or equal to 0.03% of S, less than or equal to 0.15% of Cr, more than or equal to 0.04% of Mg, and the balance of iron and other impurities.
5. The method of casting a centrifugal composite roll as claimed in claim 1, wherein: the heat preservation cover is made of heat insulation materials.
6. The method of casting a centrifugal composite roll according to claim 1, wherein: the wall thickness of the upper end of the middle layer is 1.5-3 times of that of the lower end of the middle layer.
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