CN1631579A - Visible casting method - Google Patents
Visible casting method Download PDFInfo
- Publication number
- CN1631579A CN1631579A CN 200410100470 CN200410100470A CN1631579A CN 1631579 A CN1631579 A CN 1631579A CN 200410100470 CN200410100470 CN 200410100470 CN 200410100470 A CN200410100470 A CN 200410100470A CN 1631579 A CN1631579 A CN 1631579A
- Authority
- CN
- China
- Prior art keywords
- casting
- foundry goods
- ray
- molding
- simulation
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000000034 method Methods 0.000 title claims abstract description 73
- 238000005266 casting Methods 0.000 title claims description 96
- 239000002184 metal Substances 0.000 claims abstract description 37
- 238000004088 simulation Methods 0.000 claims abstract description 22
- 239000004576 sand Substances 0.000 claims abstract description 21
- 230000007547 defect Effects 0.000 claims abstract description 14
- 238000005429 filling process Methods 0.000 claims abstract description 11
- 238000005336 cracking Methods 0.000 claims abstract description 5
- 230000033001 locomotion Effects 0.000 claims abstract description 5
- 238000012544 monitoring process Methods 0.000 claims description 19
- 238000005094 computer simulation Methods 0.000 claims description 18
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 10
- 238000007789 sealing Methods 0.000 claims description 6
- 238000013178 mathematical model Methods 0.000 claims description 4
- 238000012806 monitoring device Methods 0.000 claims description 4
- 239000003643 water by type Substances 0.000 claims description 4
- 238000007689 inspection Methods 0.000 claims description 3
- 238000012360 testing method Methods 0.000 claims description 3
- 238000007667 floating Methods 0.000 claims description 2
- 238000005259 measurement Methods 0.000 claims description 2
- 238000005406 washing Methods 0.000 claims description 2
- 238000013461 design Methods 0.000 abstract description 28
- 238000000465 moulding Methods 0.000 abstract description 14
- 229910045601 alloy Inorganic materials 0.000 abstract description 7
- 239000000956 alloy Substances 0.000 abstract description 7
- 239000011148 porous material Substances 0.000 abstract description 5
- 230000001112 coagulating effect Effects 0.000 abstract 2
- 206010000269 abscess Diseases 0.000 abstract 1
- 239000012467 final product Substances 0.000 abstract 1
- 239000000047 product Substances 0.000 abstract 1
- 208000015943 Coeliac disease Diseases 0.000 description 20
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 18
- 230000002950 deficient Effects 0.000 description 15
- 238000005516 engineering process Methods 0.000 description 13
- 230000000630 rising effect Effects 0.000 description 12
- 238000004519 manufacturing process Methods 0.000 description 10
- 238000012800 visualization Methods 0.000 description 10
- 238000003384 imaging method Methods 0.000 description 7
- 238000005495 investment casting Methods 0.000 description 6
- 238000010586 diagram Methods 0.000 description 5
- 229910001208 Crucible steel Inorganic materials 0.000 description 4
- 238000003723 Smelting Methods 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 238000011161 development Methods 0.000 description 3
- 238000002474 experimental method Methods 0.000 description 3
- 210000003128 head Anatomy 0.000 description 3
- 238000009659 non-destructive testing Methods 0.000 description 3
- 238000012797 qualification Methods 0.000 description 3
- 230000000007 visual effect Effects 0.000 description 3
- 229920000742 Cotton Polymers 0.000 description 2
- 208000037656 Respiratory Sounds Diseases 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000005457 optimization Methods 0.000 description 2
- 238000004321 preservation Methods 0.000 description 2
- 238000007528 sand casting Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 238000013519 translation Methods 0.000 description 2
- 229910000851 Alloy steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000003818 cinder Substances 0.000 description 1
- 239000012141 concentrate Substances 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 230000007812 deficiency Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 229910001338 liquidmetal Inorganic materials 0.000 description 1
- 238000010120 permanent mold casting Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000012163 sequencing technique Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
Images
Landscapes
- Analysing Materials By The Use Of Radiation (AREA)
Abstract
The invention relates to a visible molding technique more exactly a 'able to be seen' molding technique. The invention begins with adopting calculating the coagulating and mould filling process by numerical simulation techniques to forecast and reduce (or even eliminate) the normal abscess, rarefaction, heat cracking and other defects on the molding; and then real-time monitor the molding filling and coagulating process with three-dimensional X-rays to penetrate the metal liquor movements in mould cavity directly sighting the air pores, inclusion and other defects which is unforeseen by simulation; finally by integrating the simulating and observation, optimize the pouring system design so to produce the final fine moldings. The invention provides the china molding industry with a visible molding technique which achieves power and consumption saving, alleviating the pressure on environment and resource short, increasing the molding passing rate and technical product rate, lower the processing recess and being close to final product. It is adapted to molding processes of normal sand mould molding, accurate molding of different alloy and size.
Description
Technical field
The invention belongs to casting field, specifically is exactly a kind of visible casting method.It is applicable to the casting forming process of various alloys such as ordinary sand casting, hot investment casting, permanent mold casting and various sizes.
Background technology
The Chinese manufacturing added value accounts for about 37% of national GDP, is the mainstay of China's economic.And casting is the important step of equipment manufacture, for machinery manufacturing industry provides parts.China becomes the castings production base in the world just gradually, become first in the world castings production state from calendar year 2001, but China is not casting power.Cause this situation mainly to be because technology falls behind, most of Foundry Production dependence experience, particularly Design of Runner System are continued to use obsolete techniques decades ago always.Castings production energy consumption height, raw materials consumption height, rejection rate height, product yield are low.Particularly heavy castings concentrate on big and " three holes one are split " (being pore, cinder hole, shrinkage cavity and the crackle) defective of process redundancy.According to statistics, material and energy input account for 55%～50% of the output value in the Chinese manufacturing castings production process.China's cast steel piece craft yield rate average out to 50% is than external low 20%.Address these problems basic outlet and be with the new technology that using IT to propel industrialization, carry out the foundry engieering innovation energetically, reach that people-oriented, improve the quality, save resource, the energy, improve environment, realize sustainable development.
Not visible and the uncontrollability of the casting process that the casting process of " moulding of opening eyes, the cast of closing one's eyes " causes is the main cause that foundry goods produces defective.In order to make casting process visual, founder author at first attempts the water analogue technique, and water replaces molten metal to observe cavity filling process.The optimal design that water is modeled as running gate system provides important references, but water is not metal, and its shortcoming is that temperature and viscosity change are arranged unlike molten metal in cavity filling process, and therefore in essence, the effect that the water simulation is played is limited.
Along with numerical simulation technology and the theoretical development of modern casting, the especially three-dimensional temperature field simulation of casting numerical simulation technology, flow field simulation and elastic-plastic behavior stress field simulation enter the practical stage.Develop a lot of simulation softwards in the world and predicted defectives such as shrinkage cavity is loose, hot tearing.According to the simulation of Temperature result, can conclude the sequencing of casting solidification, whether the feeding passage is unimpeded; Can predict the hot cracking tendency of foundry goods in process of setting according to the analog result of stress.Utilize these analog results to carry out technological design and optimize the cycle can shorten trial production, the rate of reducing the number of rejects and seconds, and then reduce cost.The advantage of computer simulation is, as long as have the thermal physical property parameter of material, just can realize that foundry goods to various complicated shapes, various sizes fills type and process of setting is simulated.But computer simulation is also significantly not enough, and at first Mo Ni correctness depends on the model of being set up, and model will be revised by experiment.A lot of in addition casting flaws rely on simulation to forecast at present, as pore, be mingled with, oxide film is involved in the inner crack defect that forms of molten metal.Say that in essence the computer numerical technology is just simulation also, rather than the actual observation result.
Summary of the invention
The object of the present invention is to provide a kind of visible casting method, visualization casting is exactly observable casting, computer numerical simulation and X ray monitoring in real time is integrated, by observe and simulation various sizes foundry goods fill type and process of setting, determine the casting technique of optimization, realize the near net shape casting of foundry goods.
Technical scheme of the present invention is:
A kind of visible casting method is characterized in that:
1) fills type and process of setting with computer numerical simulation simulation foundry goods;
2) applying X-ray real-time monitoring system Direct observation foundry goods fills type and process of setting;
3) integrated by simulation with actual measurement, determine the casting technique of optimizing.
What the present invention adopted the computer simulation foundry goods fills type and process of setting, forecast shrinkage cavity, rarefaction defect; According to the stress-strain field of the stress numerical mock inspection foundry goods of process of setting, and according to the hot cracking tendency of analog result prediction foundry goods in process of setting of stress; On this basis, motion state, volume gas, bubble floating and the sand washing phenomenon of molten metal in the foundry goods die cavity in the further applying X-ray real-time monitoring system Real Time Observation mold filling process of casting, to simulate with measured result integrated, computer simulation, X ray are monitored in real time and engineer testing is compared, find out the various factors that influences casting quality, determine the casting technique of optimizing.
The needed mathematical model of computer simulation of the present invention is proofreaied and correct by the X ray real-time monitoring system.
Described X ray real-time monitoring system, in three dimensional X-ray monitoring device, add an apparatus for pouring in sealing chamber, described apparatus for pouring comprise be used to put crucible water bag support, coaster, crane, sand mold, watering the wire rope of bag support by being arranged at its front end links to each other with coaster on being installed in slideway, coaster is connected with motor through first switch, the wire rope that is arranged at the casting ladle frame bottom through second switch be installed on the slideway, link together by the crane of Electric Machine Control; The 3rd switch is installed on the slideway; Coaster is connected with crane; Sand mold is placed on the objective table, and sand mold is positioned on the X-raypath.
The invention has the beneficial effects as follows:
1, the present invention adopts the X ray technology to monitor the cavity filling process of foundry goods in real time, and the flowing of die cavity, what people had really seen foundry goods first fills type and process of setting by the perspective molten metal.On this basis, traditional running gate system is optimized design, thereby has avoided many because of pouring into a mould the improper volume gas that causes and defective such as being mingled with.The weak point of X ray is that it can observe casting dimension and weight is limited, and is powerless to large piece.Therefore, the present invention is integrated with computer simulation and X ray real-time monitoring system, overcomes deficiency separately, can realize the foundry goods of all sizes is carried out the process optimization design, produces the premium casting of nearly end form (very approaching with product net shape, size).
2, the present invention is with computer simulation and the X ray casting technique that goes out nearly end form designed in conjunction, owing to avoided casting flaw, guarantee the casting stable filling type, avoided being mingled with gas and be involved in molten metal inside, therefore dead head size, foundry goods process redundancy will significantly reduce, significantly improve the qualification rate and the product yield of foundry goods, improved casting quality.
3, foundry goods of the present invention fills type, solidifies and the casting method comparison of defect diagonsis and tradition " moulding of opening eyes, the cast of closing one's eyes ", and essential distinction is that it can have an X-rayed and Real Time Observation, and visualization casting thought and implementation method are great innovations of casting field.
4, the needed mathematical model of computer simulation of the present invention can be proofreaied and correct by the X ray real-time monitoring system.
5, because observed casting weight, the wall thickness of X ray real-time monitoring system is limited, and calculate the skill numerical simulation technology can simulate arbitrary dimension, wall thickness and weight foundry goods fill type and process of setting, so the observations of X ray can embody on bigger foundry goods by method for computer simulation.
6, the present invention can determine the definite of casting technological parameter, especially pouring temperature exactly, and method for visualizing can calculate the liquidus temperature of molten metal, so the deviation of pouring temperature can be determined within 10 ℃.
7, the present invention can determine foundry goods physical dimension exactly, owing to can not predict the contraction result of foundry goods in the past, so the process redundancy of foundry goods is bigger, utilizes method for visualizing, and process redundancy reduces 1/3.
8, the present invention can determine the deformation direction of foundry goods exactly, especially the foundry goods of complicated shape such as large-scale blade, there is not method for visualizing to be difficult to determine deformation direction, utilize method for visualizing, can provide deformation direction, in mould is made, provide reversible deformation, make the foundry goods of producing just in time meet size.
9, the external 3 D X-ray system equipment that utilization of the present invention is purchased, carry out secondary development, developed the improved system equipment that to monitor usefulness as visualization casting in real time, adopt the present invention not only can observe foundry goods and fill type and process of setting, improve Design of Runner System, make the casting process of traditional " moulding of opening eyes; the cast of closing one's eyes " become history, and can accurately diagnose defective locations and size behind the casting forming, has high-precision Non-Destructive Testing function, making the visual possibility that becomes of foundry goods, for casting technique provides an innovation formula technology path, also is the breakthrough of a matter of traditional handicraft.
Description of drawings
Fig. 1 is large cast steel support roller shrinkage cavity forecast.
Fig. 2 is the prediction of large cast steel support roller hot cracking tendency.
The nearly end form super-steel central body of frog of Fig. 3 for adopting visible casting method to produce.
Fig. 4 is a process flow diagram of the present invention.
Fig. 5 is the three dimensional X-ray monitoring device structural representation.
Fig. 6-1 is an apparatus for pouring structural representation of the present invention.
Fig. 6-2 is the circuit theory diagrams of coaster in the apparatus for pouring of the present invention and crane work.
Fig. 7 is X-ray equipment among Fig. 5, objective table, imaging system structural representation.
Fig. 8 is an one embodiment of the invention rising pouring blade wax-pattern combination synoptic diagram.
Fig. 9 is one embodiment of the invention rising pouring blade casting process Real Time Observation result.
Figure 10 is a comparative example teeming of the present invention blade wax-pattern combination synoptic diagram.
Figure 11 is a comparative example teeming of the present invention blade casting process Real Time Observation result.
Embodiment
Shown in Fig. 1-4, detailed content division of the present invention is as follows:
1) integrated computer modeling technique and X ray method of real-time
The X ray real time monitoring is a foundation of computer simulation, based on the Real Time Observation of X ray, and authenticating computer analog result effectively.By revising the mathematical model and the numerical computation method in flow field and temperature field, the numerical result of mistake can be avoided, and realizes that analog result and experimental result are corresponding one by one.Can determine the Design of Runner System cardinal rule of different-alloy and difformity foundry goods by the X ray real-time monitoring system, can observe pore that analogy method can't forecast, defective such as be mingled with.But the size and the weight of the observed foundry goods of its energy are limited, mainly are applicable to small articles and equal proportion simulating piece.And computer simulation can be carried out analog computation to the foundry goods of various complicated shapes and dimensions, is not subjected to the restriction of weight and size.Fig. 1 is the shrinkage cavity analog result of 50 tons large cast steel support roller, size and the position that can clearly forecast shrinkage cavity.Fig. 2 is hot tearing forecast result, is prone to crack defect at the body of roll and junction, top roll footpath.By optimizing technological design, obtain qualified roll foundry goods.And big like this foundry goods can't carry out the X ray Real Time Observation, but by computer simulation, can design the technology of roll well, obtains satisfied result.Have only the running gate system that computer simulation is combined and just can design with X ray, what cover all foundry goods fills type and process of setting.
2) casting Technology Design of nearly end form
Fit at X ray Real Time Observation, computer mould on the basis of a large amount of pouring experiment, (perhaps be referred to as the nature running gate system by adopting with the stream running gate system, Naturally pressurized filling system) helps system and be full of, keep steady flow condition, speed-controllable.The design of running gate system comprises sprue cup, sprue, cross gate, ingate and rising head five parts.The design of sprue cup is based on the stable type, the thought of favourable scum silica frost of filling.The design of sprue should be satisfied molten metal and be in full state.Cross gate should reduce the mobile speed of molten metal, remains full of state.The final filling velocity of ingate decision molten metal, ingate also should remain full of state.Because avoided being mingled with, defectives such as pore, shrinkage cavity are loose, hot tearing, the dead head design is optimized, it is minimum that the running gate system size design can reach, it is minimum that foundry goods process redundancy also reduces to.Such technological design has improved the qualification rate and the product yield of foundry goods, has realized the near net shape casting of foundry goods, helps saving energy and reduce the cost, and helps reducing foundry goods process redundancy, helps improving the quality of foundry goods.Fig. 3 is the super-steel railroad frog heart rail that adopts visible casting method to produce, because the inherent quality of foundry goods is good, online military service back is by 300,000,000 tons of gross weights, and be 3 times of traditional fusion cast frog serviceable life.Compare with wrought alloy steel core rail assembled frog, under serviceable life identical situation, optimize technological design by visualization casting, cost has reduced by 1 times, and product yield can reach 75%, and uses safer.
The present invention adopts the visualization casting technology, compares by computer simulation, X ray observation and engineer testing, finds out the various factors that influences casting deformation.Adopt new Pouring System Design Method, simulation is compared repeatedly with experiment, determines the best casting technique of foundry goods, and technological parameter reasonable in design is produced premium casting.Concrete scheme and route are as shown in Figure 4.
Running gate system of the present invention adopts Chinese patent application, and (application number is 200310105217.0, November 28 2003 applying date) Pouring System Design Method of mentioning designs, steadily filling the type running gate system according to the equal no air gap of principle design of flow makes running channel remain full of state, such design has guaranteed that molten metal is in full state constantly in running gate system, steady in the cavity filling process, prevent that gas and oxide film are involved in the molten metal, cause crackle and rarefaction defect.
At present, German Ai Kefa company produces a kind of 3 D X-ray system equipment (as: DP435 type), and this complete equipment can be used for the defects detection of solid-state foundry goods, the precision height.But such equipment can not be used for monitoring the casting dynamic process.
Shown in Fig. 5-7, in order to realize casting visualization real-time monitoring, real-time monitoring system of the present invention is based on DP435 type 3 D X-ray system equipment (RadioScopic Inspection System), add an apparatus for pouring in sealing chamber, this 3 D X-ray system equipment mainly comprises switch board 1, X-ray equipment 2, control module 4, UXGA monitor 5, X-ray monitor 6, supervisory control desk 7, both hands control desk 8, objective table 20, imaging system 22, (referring to Fig. 5,6-1,7), for the purpose of fully, the above X-ray equipment 2, objective table 20, imaging system 22 all is enclosed in one and is made in the sealing chamber that has sliding gate 9 by stereotype, X-ray equipment 2 and the corresponding setting of article on the objective table 20, after handling by control module 4, the signal that imaging system 22 receives receiver 19 delivers to UXGA monitor 5, X-ray monitor 6, supervisory control desk 7 or 20 motions of both hands control desk 8 control objective tables; Described apparatus for pouring comprises: what be used to put casting ladle waters bag support 12, coaster 13, crane 14 (present embodiment adopts 250 kilograms of small crane), sand mold, wire rope, watering the wire rope of bag support 12 by being arranged at its front end links to each other with coaster 13 on being installed in slideway, coaster 13 is connected with motor through first K switch 1, by motor (two-way type) control, be used to control moving ahead or retreating of coaster 13; Coaster 13 links to each other by wire rope with crane 14 on being installed in slideway, and coaster 13 drives cranes 14 and do transverse movement on slideway; The wire rope that waters bag support 12 bottoms is connected on the crane 14, and second switch K2 control crane motor makes the wire rope pulling water bag support and moves up and down with the control casting process; The 3rd K switch 3 is installed on the slideway, is used for the spacing of coaster 13; Sand mold 18 is placed on the objective table 20, forms foundry goods 11 after the casting complete; Sand mold 18 is positioned on X-ray 10 paths; Behind sand mold 18,, be used for observation from the X-ray 10 of X-ray equipment 2 by receiver 19 reception information.
Shown in Fig. 6-2, first and second K switch 1, K2 are open and shut valve, terminals a, the b of first K switch 1 be connected to respectively supratrochlear coaster move ahead the end A, coaster 13 retreats end B, second switch K2 terminals c, d respectively with crane 14 on crane promote end C, crane descends and holds D to be electrically connected, and the 3rd K switch 3 is a travel switch, and its folding is by coaster 13 position control.Its principle of work: put terminals a position when first K switch 1, coaster 13 moves ahead; Coaster 13 retreats when first K switch 1 is put terminals b position.Second switch K2 puts terminals c position, and crane 14 is mentioned wire rope, the upset casting ladle; When second switch K2 put terminals d position, crane 14 put down wire rope, and casting ladle resets.The 3rd K switch 3 is normally closed travel switch, and when coaster 13 bumped against the 3rd K switch 3, the 3rd K switch 3 was opened, and coaster 13 cuts off the power supply automatically, when coaster 13 returns, drives the 3rd K switch 3 and resets, and makes the 3rd K switch 3 get back to normally off automatically.
Sealing chamber has double-deck extending type sliding gate 9, seals during work, opens after the cast.After pouring into a mould required molten metal and smelting, pour casting ladle into, send sealing chamber to, pour into a mould, be poured in the sand mold 18 by induction furnace.Casting process is shown in Fig. 6-1.Open X-ray equipment 2 in the present device, UXGA monitor 5, X-ray monitor 6, imaging system 22 in the time of cast, carry out real time record, also can on display screen, observe by switch board 1, control module 4, control desk.Molten metal can clearly be observed at the generation and the floating-upward process of flow state, gas and the snotter of sprue, cross gate, ingate.
Adopt the present invention can realize visualization casting, be exemplified below:
1) Real Time Observation and record foundry goods fill type and process of setting
The concrete course of work is:
The first step is made sand mold, smelting metal liquid.
Second step was opened sliding gate 9, and sand mold 18 is placed on the objective table 20; Shut sliding gate 9, open X-ray equipment 2, adjust objective table 20 positions, observe the die cavity of sand mold 18, enter up to die cavity till the visual field of X-ray equipment 2.Close X-ray equipment 2, open sliding gate 9.
Second step was put an empty crucible as casting ladle watering on the bag support 12, open coaster 13 initiate keies, start coaster 13, coaster 13 drives casting ladle and moves in closed chamber, after casting ladle runs to sand mold 18 tops, starting crane 14, the upset of wire rope pulling casting ladle is aimed at the casting ladle outlet with sand mold 18 sprues inlet; After the position is determined, according to this set positions travel switch.
The 3rd step will water bag support 12 and coaster 13 resets, and takes off and water bag support 12 overhead crucibles.
The 4th step was taken off the crucible that molten metal is housed from smelting furnace, the crucible that molten metal is housed is placed on waters on the bag support 12, started coaster 13, after coaster 13 runs into travel switch, stopped automatically.
The 5th step was shut sliding gate 9, opened X-ray equipment 2, carried out real time record.Start crane 14, the casting ladle of molten metal is equipped with in upset, and molten metal is poured into sand mold 18, progressively finishes casting process, forms foundry goods 11.In the casting process, the flow process of molten metal carries out Real Time Observation then through receiver 19 and imaging system 22 imagings on the display screen of UXGA monitor 5, X-ray monitor 6.All observationss have also been noted simultaneously.
2) result according to the observation designs new running gate system, makes the casting stable filling type, is full of type.
Can find by observing whether can molten metal steadily be full of running gate system, exist the turbulent flow phenomenon; The flowing velocity of record molten metal arrives the time of diverse location etc.Whether the size design that can judge running gate system in view of the above is reasonable.If unreasonable, can directly find out the unreasonable part of design, so that time update.As: the cast of result and actual part is found according to the observation, and when molten metal steadily is full of running gate system, the speed when entering sand mold 18 is during less than 0.5m/s, inherent quality the best of foundry goods.It is most important that molten metal steadily fills type, and it can avoid rolling up the gas defective, washes away being mingled with that the type cornice comes to be involved in defective, also avoided because the surface layer oxide film that high turbulences causes is involved in inner formation of molten metal is mingled with and defective such as loosen.
3) can carry out Non-Destructive Testing to the casting defect after being shaped, accurately judge the three-dimensional space position and the size of tiny flaw.
There are 7 degree of freedom in this system, can carry out translation and rotation, and synoptic diagram is seen Fig. 7.Present device has very high precision, can diagnose defective very little in the foundry goods, therefore is particularly suitable for the Non-Destructive Testing of precision castings such as Aeronautics and Astronautics.Since can translation and rotation in the observation process, therefore can accurately judge the locus and the size of defective.After the defect location, can directly be presented on the screen and record.
Shown in Figure 8, be example (number in the figure is represented: 25 is cross gate, and 31 is floamed ceramics filtrating piece) with rising pouring hot investment casting high-temperature alloy blades below: casting of molten metal weight 10kg, 5 seconds durations of pouring, 1430 ℃ of pouring temperatures, 950 ℃ of shell mould temperature.(1) place a side sprue 34 on sprue 27 next doors, sprue cup 33 and sprue 27 junctions are sealed with potsherd 32, molten metal can only flow into from side sprue 34, and rising pouring enters the blade die cavity; (2) sprue cup 33 and side sprue 34 junctions are apart from sprue cup 33 bottom 50mm, and molten metal can play good current stabilization effect after entering sprue cup 33 like this; (3) shell mould adopts the silester shell, for preventing cooling, twines heat-preservation cotton at the shell mould outside surface; (4) after molten metal poured into, rising pouring entered blade, and it is very steady to fill type, and no turbulent flow phenomenon is not found defectives such as being mingled with, loosening in the foundry goods, blade qualification rate height, and quality is intact.The rising pouring cavity filling process is seen Fig. 9 (wherein: 37 are blade, and 38 is the molten metal in the sprue 27).
Comparative example
Shown in Figure 10, present embodiment is an example with teeming hot investment casting high-temperature alloy blades: use normal pressure casting method replacement vacuum pouring investigation rising pouring and the teeming influence to mold filling process of casting.Casting of molten metal weight 10kg, 5 seconds durations of pouring, 1430 ℃ of pouring temperatures, 950 ℃ of shell mould temperature.
(1) adopts traditional handicraft, the sprue cup 33 of taper; (2) use a sprue 27, two cross gate 25 combinations, cross gate 25 both sides of upper and lower setting respectively hang 7 blades 37; (3) shell mould adopts the silester shell, for preventing cooling, twines heat-preservation cotton at the shell mould outside surface; (4) after molten metal pours into from the top, high turbulences, it is not steady to fill type, and running gate system is in and do not have full state, defective such as find in the foundry goods to be mingled with, to loosen, the blade rejection rate is very high.The teeming cavity filling process is seen Figure 11.Wherein 29 is space in the sprue, and 38 is the molten metal in the sprue.
Utilize the present invention to carry out blade visualization casting Real Time Observation, find that blade teeming and rising pouring process have remarkable difference, teeming causes the molten metal turbulent flow easily, causes significantly being mingled with and rarefaction defect; And the employing present device, after the type running gate system was steadily filled in the use rising pouring, liquid metal filling was steady in casting process, did not have volume gas and inclusion defect, and casting quality is good.Show: after three dimensional X-ray monitoring device is transformed, be applied in the casting monitoring in real time, for visualization casting has been opened a beginning.
Fig. 9 and the real-time monitoring result of X ray that is respectively high-temperature alloy blades hot investment casting rising pouring and teeming shown in Figure 11.Observe and find, teeming blade cavity filling process liquid stream is disorderly, causes inclusion defect easily.And that the rising pouring blade fills type is steady, does not have defectives such as being mingled with, loosening.
The present invention provides a kind of visualization casting technology that can realize saving energy and reduce the cost, reducing environmental resource pressure, raising casting qualified rate and product yield, minimizing process redundancy, the nearly end form of realization for Chinese foundry industry.It is applicable to the casting process of the foundry goods of different-alloys such as ordinary sand casting, hot investment casting and dimensions.
Claims (4)
1, a kind of visible casting method is characterized in that:
1) fills type and process of setting with computer numerical simulation simulation foundry goods;
2) applying X-ray real-time monitoring system Direct observation foundry goods fills type and process of setting;
3) integrated by simulation with actual measurement, determine the casting technique of optimizing.
2, according to the described visible casting method of claim 1, it is characterized in that: that adopts the computer simulation foundry goods fills type and process of setting, forecast shrinkage cavity, rarefaction defect; According to the stress-strain field of the stress numerical mock inspection foundry goods of process of setting, and according to the hot cracking tendency of analog result prediction foundry goods in process of setting of stress; On this basis, motion state, volume gas, bubble floating and the sand washing phenomenon of molten metal in the foundry goods die cavity in the further applying X-ray real-time monitoring system Real Time Observation mold filling process of casting, to simulate with measured result integrated, computer simulation, X ray are monitored in real time and engineer testing is compared, find out the various factors that influences casting quality, determine the casting technique of optimizing.
3, according to the described visible casting method of claim 1, it is characterized in that: the needed mathematical model of computer simulation is proofreaied and correct by the X ray real-time monitoring system.
4, according to the described visible casting method of claim 1, it is characterized in that: described X ray real-time monitoring system, in three dimensional X-ray monitoring device, add an apparatus for pouring in sealing chamber, described apparatus for pouring comprise be used to put crucible water bag support (12), coaster (13), crane (14), sand mold (18), watering the wire rope of bag support (12) by being arranged at its front end links to each other with coaster (13) on being installed in slideway, coaster (13) is connected with motor through first switch (K1), be arranged at the wire rope that waters bag support (12) bottom through second switch (K2) be installed on the slideway, crane (14) by Electric Machine Control links together; The 3rd switch (K3) is installed on the slideway; Coaster (13) is connected with crane (14); Sand mold (18) is placed on the objective table (20), and sand mold (18) is positioned on X-ray (10) path.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB2004101004701A CN1298466C (en) | 2004-12-24 | 2004-12-24 | Visible casting method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CNB2004101004701A CN1298466C (en) | 2004-12-24 | 2004-12-24 | Visible casting method |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1631579A true CN1631579A (en) | 2005-06-29 |
| CN1298466C CN1298466C (en) | 2007-02-07 |
Family
ID=34848032
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CNB2004101004701A Active CN1298466C (en) | 2004-12-24 | 2004-12-24 | Visible casting method |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN1298466C (en) |
Cited By (18)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101767189B (en) * | 2009-12-25 | 2011-06-29 | 中国科学院金属研究所 | Method for simulating solid phase movement in steel ingot |
| CN102211177A (en) * | 2011-05-13 | 2011-10-12 | 无锡德乾能源设备有限公司 | Casting process for stern bulb steel casting |
| CN102294466A (en) * | 2010-06-28 | 2011-12-28 | 比亚迪股份有限公司 | Method for predicting shrinkage in metal liquid solidification process |
| CN102323184A (en) * | 2011-08-12 | 2012-01-18 | 哈尔滨理工大学 | Visual testing device for liquid metal fluidity and testing method based on it |
| CN102343431A (en) * | 2011-03-15 | 2012-02-08 | 江苏凯特汽车部件有限公司 | Temperature field compensation method in semi-solid rheo-die-casting process of automobile aluminium alloy wheel |
| CN102463344A (en) * | 2010-11-10 | 2012-05-23 | 江苏凯特汽车部件有限公司 | Sequential solidification temperature field compensation method for low-pressure casting aluminum alloy wheel casting |
| CN102658354A (en) * | 2012-05-03 | 2012-09-12 | 北京新方尊铸造科技有限责任公司 | Method for visualization of casing and filling processes |
| CN102799619A (en) * | 2012-06-19 | 2012-11-28 | 北京航空航天大学 | Fault mode visual method based on three-dimensional model of product |
| CN104001875A (en) * | 2014-05-12 | 2014-08-27 | 河海大学 | Metal liquid filling type flow regime viewer |
| CN104942259A (en) * | 2015-05-20 | 2015-09-30 | 江苏凯特汽车部件有限公司 | Semi-solid forming visualization technology for automobile aluminum alloy wheel |
| CN105108092A (en) * | 2015-09-02 | 2015-12-02 | 青岛理工大学 | Method for researching movement law of nonmetallic inclusion by stirring magnetic field in continuous casting crystallizer |
| CN106735043A (en) * | 2016-12-26 | 2017-05-31 | 河南工业大学 | The bubble motion physical simulating device and its simulation casting mold of vertical centrifugal casting |
| CN106845007A (en) * | 2017-02-16 | 2017-06-13 | 重庆长安汽车股份有限公司 | A kind of method for lifting high-pressure casting cavity filling process CAE analysis precision |
| WO2017128863A1 (en) * | 2016-01-26 | 2017-08-03 | 机械科学研究总院先进制造技术研究中心 | Search algorithm-based optimization method for sand mold employing near net shape forming with digital flexible compression |
| CN107755636A (en) * | 2017-09-12 | 2018-03-06 | 东方电气集团东方汽轮机有限公司 | A kind of quick method for solving the casting deformation of combustion engine blade |
| CN110496942A (en) * | 2019-09-11 | 2019-11-26 | 武汉工控艺术制造有限公司 | A kind of casting method of Cr25Ni20Si2 high-temperature alloy casting |
| CN111710377A (en) * | 2020-05-08 | 2020-09-25 | 上海交通大学 | Test bar design method and system for evaluating influence of loose defect on mechanical property |
| CN113579202A (en) * | 2021-09-06 | 2021-11-02 | 深圳市宝田精工科技有限公司 | Pure copper die-casting equipment and process |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH10272556A (en) * | 1997-03-31 | 1998-10-13 | Nippon Steel Corp | Method for detecting flowing-out of slag and instrument therefor |
| CN1209704C (en) * | 2001-05-25 | 2005-07-06 | 中国科学院金属研究所 | Simulation method of casting cavity filling process |
| JP4052006B2 (en) * | 2002-05-16 | 2008-02-27 | トヨタ自動車株式会社 | Molding simulation method, molding simulation apparatus, molding simulation program, and computer-readable recording medium recording the molding simulation program |
-
2004
- 2004-12-24 CN CNB2004101004701A patent/CN1298466C/en active Active
Cited By (25)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101767189B (en) * | 2009-12-25 | 2011-06-29 | 中国科学院金属研究所 | Method for simulating solid phase movement in steel ingot |
| CN102294466B (en) * | 2010-06-28 | 2014-07-30 | 比亚迪股份有限公司 | Method for predicting shrinkage in metal liquid solidification process |
| CN102294466A (en) * | 2010-06-28 | 2011-12-28 | 比亚迪股份有限公司 | Method for predicting shrinkage in metal liquid solidification process |
| CN102463344A (en) * | 2010-11-10 | 2012-05-23 | 江苏凯特汽车部件有限公司 | Sequential solidification temperature field compensation method for low-pressure casting aluminum alloy wheel casting |
| CN102343431A (en) * | 2011-03-15 | 2012-02-08 | 江苏凯特汽车部件有限公司 | Temperature field compensation method in semi-solid rheo-die-casting process of automobile aluminium alloy wheel |
| CN102211177A (en) * | 2011-05-13 | 2011-10-12 | 无锡德乾能源设备有限公司 | Casting process for stern bulb steel casting |
| CN102323184A (en) * | 2011-08-12 | 2012-01-18 | 哈尔滨理工大学 | Visual testing device for liquid metal fluidity and testing method based on it |
| CN102658354A (en) * | 2012-05-03 | 2012-09-12 | 北京新方尊铸造科技有限责任公司 | Method for visualization of casing and filling processes |
| CN102799619A (en) * | 2012-06-19 | 2012-11-28 | 北京航空航天大学 | Fault mode visual method based on three-dimensional model of product |
| CN102799619B (en) * | 2012-06-19 | 2014-12-03 | 北京航空航天大学 | Fault mode visual method based on three-dimensional model of product |
| CN104001875A (en) * | 2014-05-12 | 2014-08-27 | 河海大学 | Metal liquid filling type flow regime viewer |
| CN104942259A (en) * | 2015-05-20 | 2015-09-30 | 江苏凯特汽车部件有限公司 | Semi-solid forming visualization technology for automobile aluminum alloy wheel |
| CN104942259B (en) * | 2015-05-20 | 2017-03-22 | 江苏凯特汽车部件有限公司 | Semi-solid rheological forming visualization method for automobile aluminum alloy wheel |
| CN105108092A (en) * | 2015-09-02 | 2015-12-02 | 青岛理工大学 | Method for researching movement law of nonmetallic inclusion by stirring magnetic field in continuous casting crystallizer |
| CN105108092B (en) * | 2015-09-02 | 2017-03-08 | 青岛理工大学 | Method for researching movement law of nonmetallic inclusion by stirring magnetic field in continuous casting crystallizer |
| WO2017128863A1 (en) * | 2016-01-26 | 2017-08-03 | 机械科学研究总院先进制造技术研究中心 | Search algorithm-based optimization method for sand mold employing near net shape forming with digital flexible compression |
| CN106735043A (en) * | 2016-12-26 | 2017-05-31 | 河南工业大学 | The bubble motion physical simulating device and its simulation casting mold of vertical centrifugal casting |
| CN106735043B (en) * | 2016-12-26 | 2018-12-21 | 河南工业大学 | The bubble motion physical simulating device and its simulation casting mold of vertical centrifugal casting |
| CN106845007A (en) * | 2017-02-16 | 2017-06-13 | 重庆长安汽车股份有限公司 | A kind of method for lifting high-pressure casting cavity filling process CAE analysis precision |
| CN107755636A (en) * | 2017-09-12 | 2018-03-06 | 东方电气集团东方汽轮机有限公司 | A kind of quick method for solving the casting deformation of combustion engine blade |
| CN110496942A (en) * | 2019-09-11 | 2019-11-26 | 武汉工控艺术制造有限公司 | A kind of casting method of Cr25Ni20Si2 high-temperature alloy casting |
| CN111710377A (en) * | 2020-05-08 | 2020-09-25 | 上海交通大学 | Test bar design method and system for evaluating influence of loose defect on mechanical property |
| WO2021223469A1 (en) * | 2020-05-08 | 2021-11-11 | 上海交通大学 | Test rod design method and system for evaluating influence of loosening defect on mechanical property |
| CN111710377B (en) * | 2020-05-08 | 2023-05-23 | 上海交通大学 | Test bar design method and system for evaluating influence of loosening defects on mechanical properties |
| CN113579202A (en) * | 2021-09-06 | 2021-11-02 | 深圳市宝田精工科技有限公司 | Pure copper die-casting equipment and process |
Also Published As
| Publication number | Publication date |
|---|---|
| CN1298466C (en) | 2007-02-07 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN1298466C (en) | Visible casting method | |
| CN104128567B (en) | The casting method and device of brake disc disk body and thus obtained brake disc disk body | |
| CN101704069B (en) | One-box four-type casting process of brake disk | |
| CN104190874B (en) | Super-low sulfur phosphorus HTHP valve body cast shaping process | |
| CN201711492U (en) | Mold for nuclear H4 valve | |
| CN107803467B (en) | A kind of running gate system of large size valve casing class steel-casting | |
| CN103862000B (en) | A kind of end cap foundry goods core shell vertical-parting casting on flat casting technique | |
| CN103817290A (en) | Preparation method for precision casting of large-size thin-wall titanium alloy bucket body structure | |
| CN102049472A (en) | Method for casting special case casting core mould | |
| CN103846392A (en) | Casting method of steering knuckle of nodular cast iron | |
| CN106077494A (en) | A kind of pouring procedure casting VHP main beating cap | |
| CN103878322B (en) | The casting method of railcar centre of pull steel-casting | |
| CN106734922B (en) | Mold and method for nickel-base alloy permanent mold casting performance evaluation | |
| CN104139160A (en) | Casting method and device for braking disc body and braking disc body made by same | |
| CN103639361B (en) | A kind of without rising head resin sand full mold casting method | |
| CN102861894A (en) | Production method for wind power equipment stator | |
| CN203156010U (en) | Lamp cover die-casting mould | |
| CN202527690U (en) | Solidification system for manufacturing magnesium alloy casting ingot | |
| CN109719241B (en) | Short-process casting and forging integrated process for steel | |
| CN2790638Y (en) | Visulized casting real-time observing system | |
| CN102921901A (en) | Casting method for main shaft of wind generating set | |
| CN1289242C (en) | Improved structure of three dimensional X-ray monitoring device and its application | |
| CN205085354U (en) | Device of casting cylinder cap | |
| CN202621830U (en) | Precision casting dust preventing device | |
| CN206966625U (en) | A kind of dispellable mould casting pouring truck |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| PB01 | Publication | ||
| C10 | Entry into substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant | ||
| TR01 | Transfer of patent right |
Effective date of registration: 20220802 Address after: 256218 west side of middle section of Xiwang Avenue, Xiwang Industrial Park, Zouping City, Binzhou City, Shandong Province Patentee after: Zhongke Xiwang Special Steel Co.,Ltd. Address before: 110016 No. 72, Wenhua Road, Shenhe District, Liaoning, Shenyang Patentee before: INSTITUTE OF METAL RESEARCH CHINESE ACADEMY OF SCIENCES |
|
| TR01 | Transfer of patent right |