阅读说明：本技术 一种提高高锰钢辙叉内部质量且降低生产成本的方法 (Method for improving internal quality of high manganese steel frog and reducing production cost ) 是由 胡喜喜 张丽 于 2020-02-21 设计创作，主要内容包括：本发明公开一种提高高锰钢辙叉内部质量且降低生产成本的方法,涉及模型工序、造型工序、冒口去除工序；提出创新型异型冒口、易割片、辙叉结构、补贴形式、冒口去除方式,避免了传统工艺方法通过霞普气(乙炔)燃烧高温放热融化即热切方式去除冒口,节约能源,避免环境污染,且高锰钢辙叉锤击后断面外观质量高,也可从本质上避免热切冒口对辙叉轨墙局部受热不均,形成高应力区,在铸件最后凝固的组织部分集中释放产生的轨墙热裂纹报废。同时本发明增加了冒口补缩通道补贴,提高补缩通道模数,提升冒口补缩效果500％以上,提高高锰钢辙叉内部致密度,解决缩松缺陷产生,解决了传统铸造工艺方法质量瓶颈；本发明还可以回收补缩通道重新利用,节约成本。(The invention discloses a method for improving the internal quality of a high manganese steel frog and reducing the production cost, and relates to a model process, a modeling process and a riser removing process; the novel special-shaped riser, the easy-cutting piece, the frog structure, the patching form and the riser removing mode are provided, the phenomenon that the riser is removed in a hot cutting mode through the high-temperature heat release and melting of the combustion of the nephelogen gas (acetylene) in the traditional process method is avoided, the energy is saved, the environmental pollution is avoided, the appearance quality of the section of the high manganese steel frog is high after the high manganese steel frog is hammered, the phenomenon that the hot cutting riser is unevenly heated to the local part of the frog rail wall to form a high-stress area and the rail wall hot crack generated by the concentrated release of the finally solidified tissue part of the casting is scrapped can also be essentially avoided. Meanwhile, according to the invention, the feeding channel patch of the riser is added, the modulus of the feeding channel is improved, the feeding effect of the riser is improved by more than 500%, the internal density of the high manganese steel frog is improved, the shrinkage defect is overcome, and the quality bottleneck of the traditional casting process method is solved; the invention can also recover the feeding channel for reuse, thereby saving the cost.)

1. A method for improving the internal quality of a high manganese steel frog and reducing the production cost is characterized by comprising the following steps: the method is realized by the following steps:

step 1: determining the arrangement position of a riser;

step 2: according to the determined arrangement position of the dead head, a hammering platform is arranged on a back groove of the frog model;

and step 3: oblique transverse ribs are arranged on two sides of the hammering platform;

step 4, designing an annular easy-cutting piece, wherein a point on the circumferential direction of the minimum inner diameter of the inner ring of the easy-cutting piece is a stress concentration point, and the upper side and the lower side of the stress concentration point are inclined plane cuts which form an included angle of 45 degrees with the horizontal plane;

and 5: designing a special-shaped riser; the special-shaped riser consists of an upper part and a lower part, wherein the upper part is a cylindrical heating riser, and the circumferential side surface of the bottom end is inwards inclined to form a contraction port; the lower part is a cylindrical heating riser seat ring, and the inner space of the riser seat ring is used as a riser feeding channel;

step 6, fixing an easily-cut piece on the hammering platform, and fixing a special-shaped cap on the easily-cut piece;

and 7: carrying out frog casting production on the frog model provided with the knock-off lugs and the special-shaped risers obtained in the previous step, and finishing casting pouring and cooling;

and 8: after the frog is cast and the box is opened, the dead head is hammered and removed along the direction of the frog by using an air hammer;

and step 9: the high manganese steel frog is subjected to the working procedures of heat treatment, straightening, machining and the like according to related processes to form a high manganese steel frog finished product.

2. The method for improving the internal quality of the high manganese steel frog and reducing the production cost according to claim 1, characterized in that: smoothly processing the connecting part of the hammering platform and the back groove, and performing fillet processing on the edge of the upper surface of the hammering platform; and the outer diameter of the hammering platform is matched with the outer diameter of the riser seat ring.

3. The method for improving the internal quality of the high manganese steel frog and reducing the production cost according to claim 1, characterized in that: oblique horizontal muscle one side of violently muscle is connected with high manganese steel model rail wall to one side, and one side is connected with the hammering platform, and the value should satisfy:

1) the inclined transverse rib is lower than the bottom plate after the rail bottom is machined;

2) the angle of the oblique transverse rib is not more than 65 degrees;

3) the top end of the joint surface of the inclined transverse rib and the hammering platform is 5mm lower than the upper surface of the hammering platform;

4) the edges of the joint of the inclined transverse rib and the hammering platform are rounded and transitional;

5) the width of the oblique transverse rib is consistent with the thickness of the frog rail wall.

4. The method for improving the internal quality of the high manganese steel frog and reducing the production cost according to claim 1, characterized in that: the easy-cutting tablet is prepared by mixing No. 6 and No. 7 olivine sand, water glass and resin, or by mixing Luo iron ore sand and 2% resin.

5. The method for improving the internal quality of the high manganese steel frog and reducing the production cost according to claim 1, characterized in that: and horizontally hammering the air hammer along the direction of the frog to remove a dead head.

6. The method for improving the internal quality of the high manganese steel frog and reducing the production cost according to claim 1, characterized in that: the modulus of a riser is more than that of a feeding channel and more than that of a high manganese steel frog casting.

Technical Field

The invention relates to a process method, in particular to a method which is environment-friendly, can effectively improve the internal quality of a high manganese steel frog and reduce the production cost.

Background

The high manganese steel block casting frog is an important part in railway engineering equipment, and is used for bearing the repeated alternating load of pressure, impact force, vibration force and the like in the using process, and the quality of the high manganese steel block casting frog directly influences the safety and the running speed of railway transportation. Along with the requirements of speed increase and heavy load of a line, various speed-up series and heavy load series frog appear, and the requirement on the internal quality of the high manganese steel frog is higher and higher. High manganese steel frog manufacturers adopt various process methods and measures for production in order to improve the quality research of the high manganese steel frog, but the effect is poor, and the high manganese steel frog has the defects that the frog is caused to get off the road in advance due to frequent line defects such as stripping, block falling, horizontal cracks and the like, so that the driving safety is influenced.

At present, domestic high manganese steel frog manufacturers mainly adopt a common method, ester hardening, VRH and V method for molding to produce the high manganese steel frog, the production process is different according to the molding method, the frog structure and the tooling characteristics, and the manufacturers adopt corresponding process measures for producing high-quality high manganese steel frog, but have disadvantages. In order to achieve the purpose of feeding, the process is provided with a plurality of risers for feeding, as the frog back groove has a special structure, the riser feeding channel is higher, the contact area of the feeding channel and the sand tire is large, the heat dissipation is quicker, the modulus of the riser feeding channel is reduced, the feeding channel is cooled in advance, the riser feeding effect is blocked, the internal shrinkage requirement of the frog cannot be met, and the shrinkage porosity defect is formed. After a casting is unpacked, a riser is removed through a nephelogen gas (acetylene) combustion hot cutting method, in order to prevent the generation of hot cracks due to uneven heating of a frog rail wall during hot cutting, a cutting table is arranged to be high, so that more riser feeding channels cannot be recycled, and resource waste is caused. The prior international advanced high-density process with proprietary intellectual property rights also has similar problems. The high manganese steel frog line has frequent diseases, which leads to the advance of the next railway, and simultaneously, along with the design of speed increasing and heavy load of the train, the quality requirement of the line on the high manganese steel frog is more strict. Therefore, the internal quality of the high manganese steel frog must be improved.

Disclosure of Invention

In order to improve the internal quality of the high manganese steel frog, prolong the service life of the high manganese steel frog, slow down the diseases of stripping and falling blocks, horizontal cracks and the like of a high manganese steel frog line and ensure the driving safety, the invention provides the method for improving the internal quality of the high manganese steel frog and reducing the production cost, which is suitable for various types of models and various types of high manganese steel frog, not only effectively improves the internal quality of products, but also reduces the production cost, is environment-friendly and energy-saving, and has higher economic and social values.

The method for improving the internal quality of the high manganese steel frog and reducing the production cost is realized by the following steps:

step 1: and determining the arrangement position of the risers.

Step 2: and arranging a hammering platform on the back groove of the frog model according to the determined arrangement position of the dead head.

And step 3: and oblique transverse ribs are arranged on two sides of the hammering platform.

And 4, designing an annular easy-cutting piece, wherein a point on the circumferential direction of the minimum inner diameter of the inner ring of the easy-cutting piece is a stress concentration point, and the upper side and the lower side of the stress concentration point are inclined cuts forming an included angle of 45 degrees with the horizontal plane.

And 5: designing a special-shaped riser; the special riser consists of an upper part and a lower part, wherein the upper part is a cylindrical heating riser, and the circumferential side surface of the bottom end is inwards inclined to form a contraction port. The lower part is a cylindrical heating riser seat ring, and the inner space of the riser seat ring is used as a riser feeding channel.

And 6, fixing an easily-cut piece on the hammering platform, and fixing a special-shaped cap on the easily-cut piece.

And 7: and (4) carrying out frog casting production on the frog model provided with the knock-off core and the special-shaped riser obtained in the previous step, and finishing casting pouring and cooling.

And 8: and after the frog is cast and the box is opened, hammering and removing the dead head along the direction of the frog by using an air hammer.

And step 9: the high manganese steel frog is subjected to the working procedures of heat treatment, straightening, machining and the like according to related processes to form a high manganese steel frog finished product.

The invention has the advantages that:

1. the invention improves the internal quality of the high manganese steel frog and reduces the method of the production cost, the process that the main involves includes model process, molding process, dead head remove process, and design the innovative abnormal shape dead head, new easy-cutting piece, frog structure improvement, innovative form of subsidy, dead head remove mode innovation, etc., use the method of the invention to avoid the traditional process method through the burning high temperature of the Xiapu gas (acetylene) to release heat to melt, namely the dead head is removed in the hot-cutting mode, save the energy, avoid the environmental pollution, and the high manganese steel frog has high profile appearance quality after hammering, can also avoid the hot-cutting dead head from heating the rail wall part of the frog unevenly in essence, form the high stress area, the rail wall hot crack that the organization part solidified at the end of the casting releases the production is scrapped; according to the traditional hot cutting method, a feeding system adopted for preventing sand falling and rail wall cracks at a riser is low in feeding channel modulus, shrinkage porosity, shrinkage holes, thermal cracks and the like are prone to occurring at the root of the riser, and the feeding effect of the riser in the process of casting shrinkage is further blocked.

2. The method for improving the internal quality of the high manganese steel frog and reducing the production cost increases the feeding channel patch of the riser, improves the modulus of the feeding channel, improves the feeding effect of the riser by more than 500 percent, improves the internal density of the high manganese steel frog, solves the shrinkage defect and solves the quality bottleneck of the traditional casting process method.

3. The method improves the internal quality of the high manganese steel frog and reduces the production cost, and the design of the feeding structure reduces the defects of sand inclusion, sand falling, sand holes and the like.

4. The method for improving the internal quality of the high manganese steel frog and reducing the production cost can remove the hammering of the feeding channel and recycle the feeding channel for smelting again, thereby greatly saving resources.

5. The method for improving the internal quality of the high manganese steel frog and reducing the production cost is suitable for various existing modeling methods of high manganese steel manufacturers, such as: the method is suitable for various high manganese steel frog types, such as common method modeling, ester hardening modeling, VRH modeling, V method modeling and the like; for assembling the high manganese steel frog, the idea of the invention can be used for reference, but the parameters of the invention need to be adjusted.

Drawings

Fig. 1 is a schematic structural diagram of a high manganese steel block cast frog.

Fig. 2 is a side sectional view of a high manganese steel block cast frog.

FIG. 3 is a flow chart of the method for improving the internal quality of the high manganese steel frog and reducing the production cost.

Fig. 4 is a schematic view of the installation mode of a riser, a knock-off pin and a hammering platform in the method for improving the internal quality of the high manganese steel frog and reducing the production cost.

1-riser 2-hammering platform 3-back groove

4-inclined transverse rib 5-easy-cutting piece 6-frog model

101-riser race 501-stress zone

Detailed Description

The present invention will be described in further detail with reference to the accompanying drawings.

The method for improving the internal quality of the high manganese steel frog and reducing the production cost is realized by the following steps as shown in figure 1:

step 1: determining the arrangement position of a riser 1;

and calculating the modulus and the feeding distance of the risers 1 according to the thermal junctions of the frog structure and the use requirements, and determining the arrangement positions of the risers 1.

Step 2: a hammering platform 2 is arranged;

as shown in fig. 2, according to the arrangement position of the feeder head 1 determined in the step 1, a hammering platform 2 is arranged on a back groove 3 of a frog model 6, the height of the hammering platform 2 is designed to be 10mm, the diameter phi is 105mm, the inclination is 1:20, the connection part of the hammering platform 2 and the back groove 3 is smoothly processed, and the corner of the upper surface of the hammering platform 2 is rounded. Above-mentioned 2 diameters of hammering platform and inclination can suitably be adjusted according to particular case, make 2 external diameters of hammering platform and rising head seat ring 101 external diameter match, and the inclination is recommended to be 1: 20. meanwhile, the hammering platform 2 is used as a part of a riser feeding channel, the height is not too high (more than 10mm) so as to reduce a heat section and reduce the contact area of molten steel and sand tires (prevent the modulus of the channel from being reduced); meanwhile, the frog is not too low (not less than 5mm), so that the frog matrix is prevented from being damaged by the meat when the frog is hammered.

And step 3: arranging an oblique transverse rib 4;

set up oblique horizontal muscle 4 in 2 both sides of hammering platform, oblique horizontal muscle 4 is less than frog model 6 bottom plate 20 ~ 30mm with 6 rail wall tops of meeting of frog model, and the value should satisfy:

1) the inclined transverse rib 4 is lower than the bottom plate after the rail bottom is machined;

2) the inclination of the inclined transverse ribs 4 is not required to be too large, and is recommended to be not more than 65 degrees, so that the channel effect is reduced.

3) Oblique horizontal muscle 4 is less than 2 upper surfaces 5mm of hammering platform with 2 top ends that meet of hammering platform, takes meat to destroy oblique horizontal muscle 4 when preventing the hammering.

4) The edges of the joint of the inclined transverse rib 4 and the hammering platform 2 are rounded and excessive.

5) The width of the oblique transverse rib 4 is 25mm consistent with the thickness of the frog rail wall, so that a thermal node is reduced, balanced contraction is facilitated, the integrity of the frog is improved, and the stress is more balanced.

And 4, designing the easily cut sheet 5.

As shown in fig. 3, the free cutting piece 5 is annular, and the effect is better when the free cutting piece 5 is manufactured by using 6# and 7# olivine sand, water glass and resin in a ratio, or by using lolite sand and 2% resin. The easily cut pieces 5 made of olivine should be dried, and the easily cut pieces 5 made of luo-fe-ore sand may not be dried. The height of the knock-off core is 5mm, the diameter of the opening on the top surface is 80mm (the inner diameter can be properly adjusted according to products and modeling methods, so that the modulus of a riser 1 is more than the modulus of a feeding channel and more than the modulus of a casting (high manganese steel frog)), and a stress concentration point is manufactured to form a stress area 501; stress concentration point is promptly for 5 inner circles minimum inner diameters of secant piece upwards point in week, and both sides are for personally submitting the inclined plane of 45 contained angles with the level and cut about the stress concentration point, and stress concentration point place inner circle apart from the 5 top surfaces of secant piece 4mm, apart from 5 bottom surfaces of secant piece 6 mm.

And 5: and designing a special-shaped riser 1.

As shown in fig. 4, the special-shaped riser 1 is composed of an upper part and a lower part, wherein the upper part is of a cylindrical structure, and the top end of the special-shaped riser is provided with an exhaust port for inserting an exhaust pipe and exhausting air during casting; the circumferential side surface of the bottom end is inclined inwards to form a contraction opening. The lower part is a cylindrical heating riser seat ring 101, and the inner space of the riser seat ring 101 is used as a molten steel flowing channel during riser feeding, namely a riser feeding channel. In the special-shaped riser, the top cylindrical structure and the riser seat ring 101 can be fixed by two independent parts in an adhering mode, and can also be made into an integral mode. The special-shaped riser 1 plays a role in riser feeding channel patching so as to increase the modulus of a feeding channel, and the bottom of the special-shaped riser is used for being bonded with the knock-off core 5. The riser seat ring 101 has enough height, and sand shaking or sand adding is not influenced in the molding process, so that the strength of a sand tire is improved, and the defects of sand falling, sand holes, rail wall size over-tolerance and the like are prevented; the height of the special-shaped riser seat ring 101 is not too high, so that feeding of the riser 1 is affected, the function of the riser 1 is excessive, and the height of the high manganese steel frog riser seat ring 101 in the series of 50Kg/M, 75Kg/M and 60Kg/M is preferably 40-50 mm.

Step 6, installing a knock-off core 5 and a special-shaped riser 1;

and arranging the knock-off block 5 and the special-shaped riser 1 on the hammering platform 2, and fixing firmly. The free cutting piece 5 and the special-shaped riser 1 are preferably prepared and bonded before frog casting production, and the riser 1 or the free cutting piece 5 is prevented from deviating in the sand vibrating or adding process, so that the feeding effect and the hammering effect are influenced.

And 7: and (3) according to different modeling methods, carrying out frog casting production on the frog model 6 provided with the knock-off lugs 5 and the special-shaped risers 1 obtained in the previous steps, and finishing casting pouring and cooling.

And 8: after the high manganese steel frog casting is unpacked, the dead head 1 is hammered and removed along the frog direction by using an air hammer, and the hammered dead head 1 is stressed horizontally to complete the removal and the recycling of the dead head 1. The invention relates to the completion of relevant operation procedures, namely the completion of the casting hot working procedure which determines the most important internal quality of the high manganese steel frog.

And step 9: the high manganese steel frog is subjected to the working procedures of heat treatment, straightening, machining and the like according to related processes to form a high manganese steel frog finished product.

The invention meets the requirements of hot box opening and cold box opening, and the hammering effect of the cold box opening is better; in the production process of the high manganese steel frog, except the working procedures, other working procedures are normally produced according to the requirements of various modeling methods.