CN113263167A - Flange casting equipment with diameter of more than 800 mm and casting method thereof - Google Patents
Flange casting equipment with diameter of more than 800 mm and casting method thereof Download PDFInfo
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- CN113263167A CN113263167A CN202110421502.1A CN202110421502A CN113263167A CN 113263167 A CN113263167 A CN 113263167A CN 202110421502 A CN202110421502 A CN 202110421502A CN 113263167 A CN113263167 A CN 113263167A
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- 238000005266 casting Methods 0.000 title claims abstract description 60
- 238000000034 method Methods 0.000 title claims abstract description 20
- 239000002184 metal Substances 0.000 claims abstract description 196
- 229910052751 metal Inorganic materials 0.000 claims abstract description 196
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 20
- 239000010959 steel Substances 0.000 claims abstract description 20
- 229910001208 Crucible steel Inorganic materials 0.000 claims abstract description 17
- 239000004576 sand Substances 0.000 claims description 38
- 239000011449 brick Substances 0.000 claims description 34
- 239000011248 coating agent Substances 0.000 claims description 28
- 238000000576 coating method Methods 0.000 claims description 28
- 239000003110 molding sand Substances 0.000 claims description 12
- 238000003825 pressing Methods 0.000 claims description 11
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 9
- 238000001035 drying Methods 0.000 claims description 8
- 239000003973 paint Substances 0.000 claims description 8
- 238000007667 floating Methods 0.000 claims description 6
- 238000003723 Smelting Methods 0.000 claims description 4
- 239000004927 clay Substances 0.000 claims description 4
- 239000000843 powder Substances 0.000 claims description 4
- 239000011347 resin Substances 0.000 claims description 4
- 229920005989 resin Polymers 0.000 claims description 4
- 239000000126 substance Substances 0.000 claims description 4
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 3
- 229910052845 zircon Inorganic materials 0.000 claims description 3
- GFQYVLUOOAAOGM-UHFFFAOYSA-N zirconium(iv) silicate Chemical compound [Zr+4].[O-][Si]([O-])([O-])[O-] GFQYVLUOOAAOGM-UHFFFAOYSA-N 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims 1
- 239000007921 spray Substances 0.000 claims 1
- 230000008520 organization Effects 0.000 abstract description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 abstract 2
- 229910052742 iron Inorganic materials 0.000 abstract 1
- 238000001816 cooling Methods 0.000 description 25
- 238000004519 manufacturing process Methods 0.000 description 15
- 230000009970 fire resistant effect Effects 0.000 description 11
- 230000000694 effects Effects 0.000 description 8
- 230000007547 defect Effects 0.000 description 6
- 239000010410 layer Substances 0.000 description 5
- 239000007788 liquid Substances 0.000 description 5
- 239000002893 slag Substances 0.000 description 5
- 238000005242 forging Methods 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 3
- 238000004140 cleaning Methods 0.000 description 3
- 238000001514 detection method Methods 0.000 description 3
- 238000010079 rubber tapping Methods 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 210000001519 tissue Anatomy 0.000 description 3
- 210000003934 vacuole Anatomy 0.000 description 3
- 238000004364 calculation method Methods 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000006073 displacement reaction Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 238000005096 rolling process Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 238000009987 spinning Methods 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 229910020890 PHI 650 Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 239000002699 waste material 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
- B22D35/00—Equipment for conveying molten metal into beds or moulds
- B22D35/04—Equipment for conveying molten metal into beds or moulds into moulds, e.g. base plates, runners
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/06—Permanent moulds for shaped castings
- B22C9/065—Cooling or heating equipment for moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
- B22C9/24—Moulds for peculiarly-shaped castings for hollow articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D35/00—Equipment for conveying molten metal into beds or moulds
- B22D35/06—Heating or cooling equipment
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Mold Materials And Core Materials (AREA)
Abstract
本发明涉及大型厚壁铸钢法兰铸造技术领域，具体一种φ800毫米以上法兰铸造设备及其铸造方法，适用于φ800毫米以上，壁厚大于50mm以上的铸钢法兰铸造装置。包括有金属冷型Ⅰ、金属冷型Ⅱ、底座、浇注漏斗管和浇注管，金属冷型Ⅰ同轴连接在金属冷型Ⅱ上端，金属冷型Ⅱ同轴连接在底座箱圆腔上端，浇注漏斗管同轴连接在浇注管上端，浇注管同轴连接在底座箱方腔上端，金属冷型Ⅰ与金属冷型Ⅱ内部同轴连接有主砂芯。本发明铸造方法简单可行，现场操作简便，工装常规化易替代，作业安全可靠。打破传统铸钢件冒口设置方法，应用厚大金属型的强激冷理论，采用整体加高冒口的铸造方式，解决大型铸钢件间隔设置冒口、冷铁，而无法消除的内部铸造缺陷的难题，确保内部组织致密。
The invention relates to the technical field of large-scale thick-walled cast steel flange casting, in particular to a flange casting equipment with a diameter of more than 800 mm and a casting method thereof, which is suitable for a cast steel flange casting device with a diameter of more than 800 mm and a wall thickness of more than 50 mm. It includes metal cold type I, metal cold type II, base, pouring funnel pipe and pouring pipe. Metal cold type I is coaxially connected to the upper end of metal cold type II, and metal cold type II is coaxially connected to the upper end of the base box circular cavity. The funnel tube is coaxially connected to the upper end of the pouring tube, the pouring tube is coaxially connected to the upper end of the square cavity of the base box, and the metal cold type I and the metal cold type II are coaxially connected with a main sand core. The casting method of the invention is simple and feasible, the on-site operation is convenient, the routine of the tooling is easy to replace, and the operation is safe and reliable. Breaking the traditional method of setting risers for steel castings, applying the strong chilling theory of thick and large metal molds, and adopting the casting method of increasing the risers as a whole, it solves the problem of internal casting that cannot be eliminated by setting risers and cold iron at intervals for large steel castings The flawed puzzle ensures a dense internal organization.
Description
Technical Field
The invention relates to the technical field of casting of large thick-wall cast steel flanges, in particular to a flange casting tool with the diameter of more than 800 mm and a casting method thereof, which are suitable for a cast steel flange casting device with the diameter of more than 800 mm and the wall thickness of more than 50 mm.
Background
The flange, also called flange or flange, is a part for connecting the shaft with the shaft or connecting two devices, and has wide application range and large market demand. The production process of the flange mainly comprises four types of forging, casting, cutting and rolling, wherein the cutting and rolling are limited by the size of a rolled plate blank, and the manufactured flange is mainly a thin-wall flange within a certain range; the conventional manufacturing mode of the flange is mainly forging and casting, and the forged flange has high internal quality but high manufacturing cost and is limited by the tonnage of a forging hammer. The cast flange has the advantages of accurate shape, small processing amount, low manufacturing cost, larger size range, internal casting defect and shortened normal service life of the flange.
The large thick-wall cast steel flange (the maximum excircle phi of the flange is more than 800 mm, the wall thickness is more than 50mm, and the single weight is more than 300 Kg) exceeds the manufacturing range of a common forging plant, and is generally produced by adopting a casting sand mold mode. The conventional process of the steel casting comprises the following steps: placing external chill at the bottom of the excircle of the flange, uniformly distributing open risers at the top, and arranging riser feeding at the side edge of the flange; the shrinkage cavity, shrinkage porosity and slag inclusion are easily formed at the middle upper part of the large thick-wall flange blank under the influence of the shrinkage characteristic of the cast steel material; the high-quality flange requiring flaw detection cannot pass nondestructive flaw detection and cannot be put on site; even if the cable is used reluctantly, a crack source can be generated at a weak point, so that potential safety hazards exist; from the market demand and economic considerations of large thick-wall cast steel flanges, a simple and practical casting method is urgently needed to manufacture high-quality large thick-wall cast steel flanges.
Disclosure of Invention
The invention aims to provide a flange casting device with the diameter of more than 800 mm and a casting method thereof, which have simple operation, economy and practicability, ensure compact internal structure of a large thick-wall cast steel flange, achieve the use standard of the flange,
in order to solve the problems, the invention provides flange casting equipment with the diameter of more than 800 mm, which comprises a metal cooling type I, a metal cooling type II, a base box, a pouring funnel pipe and a pouring pipe, wherein the metal cooling type I and the metal cooling type II are both in a cylindrical shape, the wall thickness of the metal cooling type I and the metal cooling type II is 1.0 to 1.5 times of that of a manufactured flange, the metal cooling type I is coaxially connected to the upper end of the metal cooling type II, the inner diameters of the metal cooling type I and the metal cooling type II are different, the base box comprises a square cavity and a circular cavity, the square cavity is communicated with the circular cavity, the square cavity is arranged on the side surface of the circular cavity, the metal cooling type II is coaxially connected to the upper end of the circular cavity of the base box, the pouring funnel pipe is coaxially connected to the upper end of the pouring pipe, the pouring pipe is coaxially connected to the upper end of the square cavity, a main sand core is coaxially connected inside the metal cooling type I and the metal cooling type II, the main sand core diameter is respectively smaller than the inner diameters of the metal cooling type I and the metal cooling type II, the main psammitolite upper end is connected with the psammitolite, it equals the internal diameter of metal cold mould I to go up the psammitolite diameter, the main psammitolite, go up the psammitolite, form cavity II between I inner wall of metal cold mould and the II inner walls of metal cold mould, upward be equipped with the exhaust hole on the psammitolite, the exhaust hole is established in II upper ends of cavity, the base case, be equipped with the fire-resistant pipeline brick in pouring funnel pipe and the pouring pipe, the inside vacuole formation of fire-resistant pipeline brick is I, cavity I and II intercommunications of cavity, it has the molding sand to fill between fire-resistant pipeline brick and pouring funnel pipe or the pouring pipe, it has the molding sand to fill between base case and the fire-resistant pipeline brick. The invention utilizes the metal cold mold to replace the common sand mold, has simpler and more convenient manufacture and can be repeatedly used, when in use, the floating slag in the cavity I and the cavity II is brought to the upper surface by the self-rotation of the liquid in the bottom pouring mode after being poured from the pouring funnel pipe, thereby reducing the defects of internal organization.
Further, I up end of metal cold mould be equipped with boss I, I lower terminal surface of metal cold mould is equipped with recess I, II up ends of metal cold mould be equipped with boss II, II up ends of metal cold mould are equipped with recess II, round chamber upper end be equipped with the circular flange, the circular flange up end is equipped with boss III, boss III is connected in recess II, boss II is connected in recess I. The connection between the metal cold type I and the metal cold type II and the base adopts a mode of matching the boss with the groove, so that the connection accuracy is ensured, and the sealing effect is also improved.
Furthermore, the pouring funnel pipe comprises a funnel, a straight pipe I and a square flange II, wherein the funnel is connected to the upper end of the straight pipe I, and the square flange II is connected to the upper end of the straight pipe I. The pouring tube comprises a square flange III, a straight tube II and a square flange IV, wherein the square flange III is connected to the upper end of the straight tube II, and the square flange IV is connected to the lower end of the straight tube II. The square cavity is connected with a square flange I at the top end, the square flange I is connected to the lower end of a square flange IV, the square flange III is connected to the lower end of a square flange II, and the height of the lower end of the funnel is larger than that of the upper end of the metal cold type I. The funnel set up the convenience of use when having improved the pouring, and the funnel lower extreme height is greater than I upper end height of metal cold type, ensures going on smoothly of pouring work.
Furthermore, the refractory pipeline bricks are connected to the lower end of the cavity II from the lower end of the funnel. And the scum in the cavity I and the cavity II is brought to the upper surface by adopting a bottom injection mode and utilizing liquid spinning, so that the defects of internal tissues are reduced.
Furthermore, a clamp is connected between the square flange I and the square flange IV, a clamp is connected between the square flange III and the square flange II, a clamping groove is formed in the clamp to form a U shape, two side edges of the clamping groove are oblique edges, the square flange I and the square flange IV are connected in the clamping groove, and the square flange III and the square flange II are connected in the clamping groove. The checkpost is used for connecting unable adjustment base, pouring funnel pipe and pouring pipe, takes place the displacement and influences pouring work when preventing to pour into a mould.
Furthermore, a plurality of hanging handles I are arranged on the metal cold type I; the metal cold type II is provided with a plurality of hanging handles II, and the hanging handles II are arranged on the outer wall of the metal cold type II; the base is provided with a plurality of hanging handles III, and the hanging handles III are arranged on the outer wall of the base; the pouring funnel pipe is provided with a plurality of hanging handles IV, and the hanging handles IV are arranged on the outer wall of the pouring funnel pipe; the pouring pipe is provided with a hanging handle V, the hanging handle V is arranged on the outer wall of the pouring pipe, and the hanging handles V are arranged in a plurality. The arrangement of the hanging handle is convenient for hoisting parts, and the use convenience is improved.
Furthermore, the upper end of the upper sand core is connected with a sand core pressing block. The arrangement of the sand core pressing block prevents the main sand core and the upper sand core from displacing during pouring.
The invention relates to a casting method of flange casting equipment with the diameter of more than 800 mm, which comprises the following steps:
s1, size selection: selecting the wall thickness of a metal cold type I and a metal cold type II according to the wall thickness of a large thick-wall cast steel flange by 1-1.5 times, and selecting the total height of the metal cold type I and the metal cold type II to be larger than the total height of the flange by 100-500 mm according to the total height of the cast steel flange;
s2, manufacturing a sand core: manufacturing a main sand core and an upper sand core according to the size of the inner cavity of the flange, wherein the main sand core and the upper sand core are made of resin sand, and the outer surfaces of the main sand core and the upper sand core are coated with a coating with the thickness of 2-3 mm, wherein the coating is an alcohol-based coating;
s3, modeling: coating or sand hanging is sprayed on the inner walls of the metal cold type I and the metal cold type II, the metal cold type I, the metal cold type II, the base, the pouring funnel pipe and the pouring pipe are sequentially connected, refractory pipeline bricks are embedded in the base, the pouring funnel pipe and the pouring pipe, a cavity I is formed by the refractory pipeline bricks, and the refractory pipeline bricks are filled with molding sand and are filled with solid sand;
s4, drying: putting the metal cooling type I, the metal cooling type II and the base in the step S3 into a drying kiln to dry moisture, taking out of the kiln and airing to 200 ℃;
s5, assembling the box: cleaning sundries and floating sand on the upper surface of the base, placing the main sand core and the upper sand core into the metal cold mould I and the metal cold mould II and aligning, and connecting a sand core pressing block to the upper end of the upper sand core;
s6, pouring, smelting according to specific chemical components of the large thick-wall cast steel flange, controlling the tapping temperature at 1550 +/-20 ℃ and the pouring temperature at 1500 +/-20 ℃, and ensuring that a pouring funnel is full and is poured once without flow interruption.
Further, in the step S3, if the coating is sprayed on the inner walls of the metal cold type I and the metal cold type II, the thickness of the coating is 2mm-3mm, and the coating is water-based zircon powder.
Further, in the step S3, if sand is coated on the inner walls of the metal cold mold i and the metal cold mold ii, the thickness of the coated sand is 10mm to 15mm, and the coated sand is clay sand.
The invention has the beneficial effects that: the casting method comprises a metal cold type I, a metal cold type II, a base, a pouring funnel pipe and a pouring pipe, wherein the metal cold type I is coaxially connected to the upper end of the metal cold type II, the metal cold type II is coaxially connected to the upper end of a round cavity, the pouring funnel pipe is coaxially connected to the upper end of the pouring pipe, the pouring pipe is coaxially connected to the upper end of a square cavity, a main sand core is coaxially connected inside the metal cold type I and the metal cold type II, an upper sand core is connected to the upper end of the main sand core, a cavity II is formed between the main sand core, the upper sand core, the inner wall of the metal cold type I and the inner wall of the metal cold type II, refractory pipeline bricks are arranged in the base, the pouring funnel pipe and the pouring pipe, a cavity I is formed inside the refractory pipeline bricks, and the cavity I is communicated with the cavity II. The internal casting defects that risers are arranged at intervals on the conventional steel castings and the chill cannot be eliminated can be eliminated, and the tissue density is improved. And (4) carrying out nondestructive ultrasonic flaw detection on the steel casting by grade II.
Drawings
FIG. 1 is a cross-sectional view of the overall construction of the present invention;
FIG. 2 is a cross-sectional view of a metal cold type I of the present invention;
FIG. 3 is a cross-sectional view of the metal chill II of the present invention;
FIG. 4 is a schematic structural diagram of a base according to the present invention;
FIG. 5 is a schematic view of the construction of a pouring funnel of the present invention;
FIG. 6 is a schematic structural view of a pour tube of the present invention;
FIG. 7 is a schematic view of the clip of the present invention;
fig. 8 is a schematic structural diagram of the large thick-wall cast steel flange casting molding of the invention.
In the figure: 1. metal cooling type I; 101. a boss I; 102. a groove I; 103. a hanging handle I; 2. metal cooling type II; 201. a boss II; 202. a groove II; 203. a hanging handle II; 3. a base; 301. a square cavity; 302. a square flange I; 303. a circular cavity; 304. a circular flange; 305. a boss III; 306. a hanging handle III; 4. pouring a funnel pipe; 401. a funnel; 402. a straight pipe I; 403. a square flange II; 404. a hanging handle IV; 5. a pouring tube; 501. a square flange III; 502. a straight pipe II; 503, methodlan IV; 504. a hanging handle V; 6. a clip; 601. a card slot; 7. refractory pipeline bricks; 8. molding sand; 9. a main sand core; 10. a sand core is arranged; 1001. an exhaust hole; 11. pressing a sand core block; 12. a cavity I; 13. and a cavity II.
Detailed Description
As shown in figures 1-8, the invention relates to a flange casting device with the diameter of more than 800 mm, which comprises a metal cold type I1, a metal cold type II 2, a base box 3, a pouring funnel pipe 4 and a pouring pipe 5, wherein the metal cold type I and the metal cold type II are both in a cylindrical shape, the metal cold type I1 is coaxially connected with the upper end of the metal cold type II 2, the inner diameters of the metal cold type I and the metal cold type II are different, the exposed part of the metal cold type I and the metal cold type II in contact needs to be subjected to transition and fillet smearing by a sand layer, the base 3 comprises a square cavity 301 and a circular cavity 303, the square cavity 301 is communicated with the circular cavity 303, the square cavity 301 is arranged on the side surface of the circular cavity 303, the metal cold type II 2 is coaxially connected with the upper end of the circular cavity 303, the pouring funnel pipe 4 is coaxially connected with the upper end of the pouring funnel pipe 5, the upper end of the square cavity 301 is coaxially connected with the inner parts of the metal cold type I1 and the metal cold type II 2, a main sand core 9 is coaxially connected with the inner parts of the metal cold type I1 and the metal cold type II 2, the main sand core 9 is respectively smaller than the inner diameters of the metal cold type I1 and the metal cold type II 2, the 9 upper ends of main psammitolite are connected with sand core 10, it equals metal cold mould I1 and the II 2 internal diameters of metal cold mould to go up sand core 10 diameter, main sand core 9, go up sand core 10, vacuole formation II 13 between I1 inner wall of metal cold mould and the II 2 inner wall of metal cold mould, upward be equipped with exhaust hole 1001 on the sand core 10, exhaust hole 1001 establishes in cavity II 13 upper end, base 3, be equipped with fire-resistant pipeline brick 7 in pouring funnel pipe 4 and the pouring pipe 5, fire-resistant pipeline brick 7 is equipped with a plurality ofly, a plurality of fire-resistant pipeline bricks 7 splice piece by piece in proper order, fire-resistant pipeline brick 7 includes straight section and elbow, the inside vacuole formation I12 of fire-resistant pipeline brick 7, cavity I12 and cavity II 13 UNICOM, it has molding sand 8 to fill between fire-resistant pipeline brick 7 and pouring funnel pipe 4 and the pouring pipe 5 inner walls, you pack between case 3 and the fire-resistant pipeline brick 7 has molding sand 8.
Further, I1 up end of metal cold type be equipped with boss I101, I1 lower terminal surface of metal cold type be equipped with recess I102, II up ends of metal cold type be equipped with boss II 201, II up ends of metal cold type be equipped with recess II 202, circle chamber 303 upper end be equipped with circular flange 304, circular flange 304 up end is equipped with boss III 305, boss III 305 is connected in recess II 202, II 201 of boss are connected in recess I102.
Further, the pouring funnel pipe 4 comprises a funnel 401, a straight pipe I402 and a square flange II 403, wherein the funnel 401 is connected to the upper end of the straight pipe I402, and the square flange II 403 is connected to the upper end of the straight pipe I402. The pouring tube 5 comprises a square flange III 501, a straight tube II 502 and a square flange IV 503, wherein the square flange III 501 is connected to the upper end of the straight tube II 502, and the square flange IV 503 is connected to the lower end of the straight tube II 502. The top end of the square cavity 301 is connected with a square flange I302, the square flange I302 is connected with the lower end of a square flange IV 503, the square flange III 501 is connected with the lower end of a square flange II 403, and the height of the lower end of the funnel 401 is larger than that of the upper end of the metal cold type I1.
Further, the refractory duct brick 7 is connected from the lower end of the hopper 401 to the lower end of the cavity II 13.
Furthermore, a clamp 6 is connected between the square flange I302 and the square flange IV 503, the clamp 6 is connected between the square flange III 501 and the square flange II 403, a clamping groove 601 is formed in the clamp 6 to form a U shape, the two side edges of the clamping groove 601 are oblique edges, the square flange I302 and the square flange IV 503 are connected in the clamping groove 601, and the square flange III 501 and the square flange II 403 are connected in the clamping groove 601.
Furthermore, a plurality of hanging handles I103 are arranged on the metal cold type I1, the hanging handles I103 are arranged on the outer wall of the metal cold type I1, and the number of the hanging handles I103 is multiple; the metal cold type II 2 is provided with a plurality of hanging handles II 203, the hanging handles II 203 are arranged on the outer wall of the metal cold type II 2, and the number of the hanging handles II 203 is multiple; the base 3 is provided with a plurality of hanging handles III 306, the hanging handles III 306 are arranged on the outer wall of the base 3, and the number of the hanging handles III 306 is multiple; a plurality of hanging handles IV 404 are arranged on the pouring funnel pipe 4, the hanging handles IV 404 are arranged on the outer wall of the pouring funnel pipe 4, and the number of the hanging handles IV 404 is large; the pouring tube 5 is provided with a plurality of hanging handles V504, the hanging handles V504 are arranged on the outer wall of the pouring tube 5, and the hanging handles V504 are arranged.
Furthermore, the upper end of the upper sand core 10 is connected with a sand core pressing block 11.
The invention utilizes metal cold mold to replace common sand mold molding, the manufacture is simpler and more convenient, the metal cold mold can be recycled, when in use, the metal cold mold is poured from the pouring funnel pipe 4, the bottom pouring mode is adopted, and the scum in the cavity I12 and the cavity II 13 is brought to the upper surface by utilizing the liquid spinning, thereby reducing the internal tissue defect.
The connection between the metal cold type I1, the metal cold type II 2 and the base box 3 adopts a mode of matching a boss with a groove, so that the connection accuracy is ensured, and the sealing effect is also improved.
Funnel 401 sets up the convenience of use when having improved the pouring, and funnel 401 lower extreme height is greater than the I1 upper end height of metal cold type, ensures going on smoothly of pouring work.
The clamp 6 is used for connecting the fixed base box 3, the pouring funnel pipe 4 and the pouring pipe 5, and prevents the pouring from being influenced by the displacement during pouring.
The arrangement of the hanging handle is convenient for hoisting parts, and the use convenience is improved.
The arrangement of the sand core pressing block 11 prevents the main sand core 9 and the upper sand core 10 from displacing during casting.
The invention relates to a casting method of flange casting equipment with the diameter of more than 800 mm, which comprises the following steps:
s1, size selection: according to the wall thickness of a large thick-wall cast steel flange, the wall thicknesses of a metal cold type I1 and a metal cold type II 2 are respectively selected according to 1-1.5 times, the total height after the metal cold type I1 and the metal cold type II 2 are connected is selected according to the total height of the flange, the height of the metal cold type I1 is greater than the design height of a drawing by 100-300 mm, the metal cold type I1 is used as an integral feeding head, and the pouring water amount of the feeding head accounts for 30-40% of the total water amount;
s2, manufacturing a sand core: manufacturing a main sand core 9 and an upper sand core 10 according to the size of an inner cavity of the flange, wherein the main sand core 9 and the upper sand core 10 are made of resin sand, and the outer surfaces of the main sand core 9 and the upper sand core 10 are coated with 2-3 mm thick paint which is alcohol-based paint;
s3, modeling: the inner walls of the metal cold type I1 and the metal cold type II 2 are sprayed with paint or coated with sand, the metal cold type I1, the metal cold type II 2, the base box 3, the pouring funnel pipe 4 and the pouring pipe 5 are sequentially connected, the refractory pipeline bricks 7 are embedded in the base box 3, the pouring funnel pipe 4 and the pouring pipe 5, the refractory pipeline bricks 7 are arranged to form a cavity I12, and the refractory pipeline bricks 7 are arranged and filled with molding sand and are filled with solid sand; the inner wall extension rule of the metal cold type I1 and the metal cold type II 2 is 2-3% larger than that of the conventional steel casting;
s4, drying: putting the metal cooling type I1, the metal cooling type II 2 and the base 3 in the step S3 into a drying kiln to dry moisture, and taking out of the kiln and airing to 200 ℃;
s5, assembling the box: cleaning sundries and floating sand on the upper surface of the base 3, placing the main sand core 9 and the upper sand core 10 into the metal cold mould I1 and the metal cold mould II 2, aligning, and connecting a sand core pressing block 11 to the upper end of the upper sand core 10;
s6, pouring, smelting according to specific chemical components of the flange, controlling the tapping temperature to 1550 +/-20 ℃, controlling the pouring temperature to 1500 +/-20 ℃, and ensuring that a pouring funnel is full and is poured once without allowing flow interruption.
Further, in the step S3, if the coating is sprayed on the inner walls of the metal cooling type I1 and the metal cooling type II 2, the thickness of the coating is 2mm-3mm, and the coating is water-based zircon powder.
Further, in the step S3, if sand is coated on the inner walls of the metal cold type i 1 and the metal cold type ii 2, the thickness of the coated sand is 10mm to 15mm, and the coated sand is clay sand.
The common steel casting generally adopts uniformly distributed round or oval risers for feeding, but the root parts of the risers or shrinkage cavities appear between adjacent risers, while the cylindrical steel casting adopts integral heightening to replace riser feeding, so that the shrinkage cavities among the risers can be eliminated; according to a calculation formula of steel casting process yield = casting gross weight/casting gross weight + casting head weight multiplied by 100%, the process yield is correspondingly found to be 64-72% corresponding to the single weight of the flange and the main wall thickness, because the whole body adopts a thick-wall metal mold as an external chill, the chilling effect is enhanced, the wall thickness of the centrifugal roller mold of the type is consistent, the condition of forming a heat node is lacked, and the requirement on riser feeding is reduced. And then, through flange pouring simulation calculation, the floating of the slag in the metal liquid is confirmed, and finally formed shrinkage cavities are positioned in the range of 50-100 mm larger than the height of the flange, so that the process yield is increased to 85-89%. The total height of the metal cold type I1 and the metal cold type II 2 after connection is 200mm-500mm larger than the height of the centrifugal roller die, the molten steel temperature and the metal die temperature are considered, the influence of weather is also considered, waste is caused after the total height exceeds 500mm, the yield of the centrifugal roller die is low, and the manufacturing cost is increased.
According to the wall thickness of the large thick-wall flange, the wall thickness of the metal cold type I1 and the wall thickness of the metal cold type II 2 are selected to be less than 1.0 according to 1-1.5 times, the cold type chilling effect is poor, and the inside of the large thick-wall flange is reversely pumped to form a shrinkage cavity; and if the chilling effect is larger than 1.5, the chilling effect is increased gradually, so that riser feeding is influenced.
Before baking, spraying coating or sand hanging on the inner walls of the metal cold type I1 and the metal cold type II 2 is finished, only the metal cold type I1, the metal cold type II 2 and the base 3 are baked when the metal cold type I1 and the metal cold type II 2 are placed into a drying kiln, the refractory pipeline brick 7 is embedded in the base box 3, and the pouring funnel pipe 4 and the pouring pipe 5 are molded and dried in advance.
Spraying coating on the inner walls of the metal cold type I1 and the metal cold type II 2, wherein the thickness of the coating is 2mm-3 mm; the coating layer with the thickness of 2mm-3mm can be tightly attached to the inner wall of the cold mold, so that the cold mold is protected; when the thickness of the coating is less than 2mm, the coating is too thin, the formed protective film has weak points, the molten steel filled into the cavity is broken through, the molten steel is adhered to the cold mold, the appearance quality of the flange is affected, and the inner wall of the cold mold is seriously damaged; when the coating is larger than 3mm, the coating can peel and burst, and the coating is also broken by the molten steel filled into the cavity.
The inner walls of the metal cold type I1 and the metal cold type II 2 are coated with sand, and the thickness of the coated sand is 10mm-15 mm; the sand layer is less than 10mm, the strength is poor, and the impact of molten steel cannot be resisted; the sand layer is larger than 15mm, the cold type chilling effect is gradually reduced, and the dendritic direction of the inner wall of the large thick-wall flange is influenced; when the thickness of the sand layer is gradually increased from 10mm to 15mm, the strength of the molding sand is enhanced, the cold type chilling effect is reduced, and the optimal sand layer thickness is 12.5 mm.
The coating with the thickness of 2mm-3mm is coated on the outer surfaces of the main sand core 9 and the upper sand core 10 so as to form a shell to protect the sand cores from being broken by molten steel, the purity of the molten steel is ensured to be less than 2mm, the coating is too thin, the formed protective film has weak points, the molten steel filled into the cavity is broken through, the molten steel is adhered to a cold mold, the appearance quality of a large thick-wall flange is influenced, and the inner wall of the cold mold is seriously damaged; when the coating is larger than 3mm, the coating can peel and burst, and the coating is also broken by the molten steel filled into the cavity.
Example (b):
taking phi 900/phi 600 x 232mm flange, wall thickness 60mm, material ZG42CrMo, net single weight 0.357 ton as an example, by using the method of the invention,
s1, size selection: the wall thickness of the flange with phi 900/phi 600 and 232mm is 60mm, the processing amount and the extension rule are placed on the inner circle and the outer circle, and the wall thickness is increased to 85 mm. According to the following steps of 1: 1.5, selecting the wall thickness of the metal cold type I1 and the metal cold type II 2 to be not less than 100mm, and selecting the combination height to exceed the net size of the flange by 100 mm;
s2, manufacturing a sand core: calculating the size of the sand core to be phi 650 multiplied by 450mm according to the size of a phi 900/phi 600 multiplied by 232mm flange, adopting resin sand to manufacture the core in a segmented manner, and accumulating the total height to reach the standard;
s3, modeling: 12mm of sand is hung on the inner walls of the metal cold type I1 and the metal cold type II 2, the metal cold type I1, the metal cold type II 2, the base box 3, the pouring funnel pipe 4 and the pouring pipe 5 are sequentially connected, a refractory pipeline brick 7 is embedded in the base box 3, the pouring funnel pipe 4 and the pouring pipe 5, a cavity I12 is formed by arranging the refractory pipeline brick 7, and the refractory pipeline brick 7 is filled with molding sand and is solid;
s4, drying: putting the metal cooling type I1, the metal cooling type II 2 and the base 3 in the step S3 into a drying kiln to dry moisture, and taking out of the kiln and airing to 200 ℃;
s5, assembling the box: cleaning sundries and floating sand on the upper surface of the base 3, placing the main sand core 9 and the upper sand core 10 into the metal cold mould I1 and the metal cold mould II 2, aligning, and connecting a sand core pressing block 11 to the upper end of the upper sand core 10;
s6, pouring, smelting according to the chemical components of ZG42CrMo, controlling the tapping temperature at 1550 +/-10 ℃ and the pouring temperature at 1500 +/-10 ℃, and ensuring that a pouring funnel is full and is poured once without allowing flow interruption.
The method is characterized in that a shrinkage cavity which is floated and finally formed by slag in the metal liquid is positioned at 232mm + 50-100 mm, the uppermost end of a flange is shrunk by 80mm after solidification, the part mainly comprises scum, casting powder and the shrinkage cavity, the cut riser head allowance is 232mm +30mm, fine shrinkage cavities and slag inclusions exist in the end face, defects are eliminated when the end face is machined to 232mm, and the internal organization is detected to be compact by ultrasonic wave to reach a secondary standard.
Claims (10)
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