阅读说明：本技术 一种风电铸件低补贴量铸造工艺 (Low-allowance casting process for wind power casting ) 是由 缪亚兵 吕飞 赵栋 许强威 陈宇 于 2021-01-20 设计创作，主要内容包括：本发明涉及一种风电铸件低补贴量铸造工艺,属于铁水铸造技术领域。涉及(1)直驱型底座铸件的补贴量设计：将球面前后两侧自下而上依次划分为下过渡区域、侧面分型面区域、上过渡区域和顶部区域,对应的补贴量分别为+2mm～0mm渐变、0、+3mm～0渐变和0～5mm；(2)双馈型半封闭底座铸件的补贴量设计：竖立铸造时将肚皮区域中心位置的补贴量放置为-3～0mm,顶端和底端的铸造补贴量放置为0mm,自中心位置向顶端或底端的补贴量均匀过渡；(3)轮毂铸件的补贴量设计：盖箱法兰端面及电机孔的补贴量为+14～16mm,底箱法兰端面和叶片法兰端面的补贴量为+11～+13mm,球面以及筋板面壁厚若取正负公差则不放补贴量即补贴量为0,若取正公差则补贴量为公差带的1/3。(The invention relates to a low-subsiding-amount casting process for a wind power casting, and belongs to the technical field of molten iron casting. Relating to (1) the design of the patching quantity of a direct-drive base casting: sequentially dividing the front side and the rear side of the spherical surface into a lower transition area, a side parting surface area, an upper transition area and a top area from bottom to top, wherein the corresponding patching amounts are respectively +2 mm-0 mm gradual change, 0, +3 mm-0 gradual change and 0-5 mm; (2) and (3) patching quantity design of the double-fed semi-closed base casting: when the casting is vertically carried out, the patching quantity of the center position of the belly area is set to be-3-0 mm, the casting patching quantity of the top end and the bottom end is set to be 0mm, and the patching quantity is uniformly transited from the center position to the top end or the bottom end; (3) and (3) patch amount design of the hub casting: the patching quantity of the flange end face of the cover box and the motor hole is + 14-16 mm, the patching quantity of the flange end face of the bottom box and the flange end face of the blade is + 11-13 mm, if the wall thickness of the spherical surface and the rib plate surface is within a positive tolerance, the patching quantity is not released, namely the patching quantity is 0, and if the wall thickness is within a positive tolerance, the patching quantity is 1/3 of a tolerance zone.)

1. The casting process with the low patching quantity for the wind power casting is characterized in that: to

(1) The patching quantity design of the direct-drive base casting comprises the following steps: the direct-drive base casting comprises a spherical surface, wherein a bottom flange end face, an inclined flange end face and a side flange end face are arranged on the spherical surface, the inclined flange end face and the side flange end face are respectively positioned on the left side and the right side of the spherical surface, the front side and the rear side of the spherical surface are respectively and sequentially divided into a lower transition area, a side parting surface area, an upper transition area and a top area from bottom to top, the side parting surface area corresponds to a middle section spherical area with the cast wall thickness rising by 6% -10%, the patching quantity corresponding to the side parting surface area is 0, the patching quantity of the lower transition area is gradually reduced from top to bottom in a range of +2 mm-0, the patching quantity of the upper transition area is gradually reduced from top to bottom in a range of +3 mm-0, and the patching quantity of the top area is 0-5 mm;

or (2) the patching quantity design of the double-fed semi-closed base casting: the double-fed type semi-closed base comprises a bottom flange and a top flange, an arc surface, namely a belly region, is formed downwards and inwards from the end face of the top flange, the double-fed type semi-closed base is vertically arranged in a left-right direction by the top flange and the bottom flange when being cast, so that the belly region is vertically arranged, the casting patch amount of the center position of the belly region is set to be-3-0 mm, the casting patch amount of the top end is set to be 0mm, the casting patch amount of the bottom end is set to be 0mm, the patch amounts from the center position to the top end are uniformly transited, and the patch amounts from the center position to the bottom end are uniformly transited;

or (3) the patch amount design of the hub casting: the hub comprises a cover box flange at the top, a bottom box flange at the bottom, three blade flanges which mutually form 120 degrees and a spherical surface for connecting the five flanges, the port of each blade flange is provided with a rib plate surface, a motor hole and a plurality of lugs are arranged on the rib plate surface, the patching amount of the end surface of the cover box flange and the motor hole is + 14-16 mm, the patching amount of the end surface of the bottom box flange and the end surface of the blade flange is + 11- +13mm, if the wall thickness of the spherical surface and the rib plate surface is within a positive tolerance, the patching amount is not released, namely 0, if the wall thickness of the spherical surface and the rib plate surface is within a positive tolerance, 1/3 of a tolerance band is adopted, the patching amount of the lug end surface of the lug needing to be completed by a fitter is 8-10 mm, the patching amount of the lug end surface of a screw hole on the lug deviated to the edge of the lug is 2-3mm, and the patching amount of the lug end surface in other.

2. The low-allowance casting process of the wind power casting according to claim 1, wherein: the top of the side flange end surface starts from the top of the spherical surface, and the bottom approaches to the bottom of the spherical surface.

3. The low-allowance casting process of the wind power casting according to claim 2, wherein: on any one side of the front side and the rear side of the spherical surface, the central angle of the top area on the circular section of the side flange end surface is 30 degrees, the central angle of the upper transition area on the circular section of the side flange end surface is 35 degrees, the central angle of the side parting surface area on the circular section of the side flange end surface is 50 degrees, and the central angle of the lower transition area on the circular section of the side flange end surface is 65 degrees.

4. The wind power casting low-subsiding-amount casting process according to claim 1, 2 or 3, wherein: the patching quantity design of the direct-drive base casting is suitable for power: 1.5MW-6MW, tonnage: and placing the spherical patch of the direct-drive base casting of 6T-50T.

5. The low-allowance casting process of the wind power casting according to claim 1, wherein: the central part of the belly area of the doubly-fed semi-closed base has the largest tendency of wall thickness expansion, the tendency of the wall thickness expansion is gradually reduced along the upper and lower sides, and the wall thickness is expanded by 7% -12% during casting.

6. The wind power casting low-subsiding-amount casting process according to claim 1 or 5, wherein: the patch design of the double-fed semi-closed base is suitable for power: 1.5MW-5MW, tonnage: the casting patch of the belly area of the 10T-40T double-fed semi-closed base is placed, and the belly area belongs to the non-machined surface area.

7. The low-allowance casting process of the wind power casting according to claim 1, wherein: in the design of the patching amount of the hub casting, the placement patching amount of the upper plane of the bottom box flange is plus 5mm, and the upper plane of the bottom box flange is in transition with the spherical surface around the bottom box flange.

8. The low-allowance casting process of the wind power casting according to claim 1, wherein: the patch design of the hub casting is applicable to power: 1.5MW-5MW, tonnage: 10T-50T wind power hub.

9. The low-allowance casting process of the wind power casting according to claim 1, wherein: for direct-drive type base castings and/or double-fed type semi-closed base castings, the casting rigidity is also considered to be improved during casting, a sand box is placed in a pit, molding sand is filled in the sand box, the sand box and the wall body of the pit are supported through steel pipes, and a plurality of steel pipes are symmetrically supported around the sand box.

10. The low-allowance casting process of the wind power casting according to claim 1, wherein: for direct-drive type base castings and/or double-fed type semi-closed base castings, the casting mold rigidity is required to be improved during casting, a sand box is placed in a pit, molding sand is filled in the sand box, a tension rod is arranged on the sand box, and two ends of the tension rod are respectively in locking connection with the sand box.

Technical Field

The invention belongs to the field of wind power casting, and particularly relates to a casting process of wind power wheel hubs and base castings.

Background

The production and casting process of the wind power casting is mainly manual manufacturing, equipment is assisted, slight deviation exists in the size of the casting in the production process, the allowance can be prevented from causing insufficient wall thickness due to the deviation for placing the casting, machining allowance is reserved for machining, no clear process is provided for placing the allowance for the wind power casting at present, the traditional method is that the allowance is uniformly placed for all areas of the casting, the wall thickness of the casting is out of tolerance and the casting is overweight, the amount of molten iron is increased, and the difficulty and complexity of machining can be increased even.

Therefore, a proper subsiding amount needs to be designed for the wind power casting, the casting process with the low subsiding amount of the wind power casting is realized, the utilization rate of molten iron is improved, and the processing of subsequent castings is simplified.

Disclosure of Invention

Aiming at the prior art, the inventor of the application provides a method for reasonably placing the patch amount by analyzing various machine type structures and collecting data, the patch amount is placed aiming at the casting structure, finally the size and the weight of the casting can be controlled, the method is used for guiding the setting of the casting patch amount of the wind power casting to realize the low patch amount casting of the wind power casting, and the patch amount refers to the thickening on the surface.

The technical scheme adopted by the invention for solving the problems is as follows: a low-subsiding-amount casting process for wind power castings relates to

(1) The patching quantity design of the direct-drive base casting comprises the following steps: the direct-drive base casting comprises a spherical surface, wherein a bottom flange end face, an inclined flange end face and a side flange end face are arranged on the spherical surface, the inclined flange end face and the side flange end face are respectively positioned on the left side and the right side of the spherical surface, the front side and the rear side of the spherical surface are respectively and sequentially divided into a lower transition area, a side parting surface area, an upper transition area and a top area from bottom to top, the side parting surface area corresponds to a middle section spherical area with the cast wall thickness rising by 6% -10%, the patching quantity corresponding to the side parting surface area is 0, the patching quantity of the lower transition area is gradually reduced from top to bottom in a range of +2 mm-0, the patching quantity of the upper transition area is gradually reduced from top to bottom in a range of +3 mm-0, and the patching quantity of the top area is 0-5 mm;

or (2) the patching quantity design of the double-fed semi-closed base casting: the double-fed type semi-closed base comprises a bottom flange and a top flange, an arc surface, namely a belly region, is formed downwards and inwards from the end face of the top flange, the double-fed type semi-closed base is vertically arranged in a left-right direction by the top flange and the bottom flange when being cast, so that the belly region is vertically arranged, the casting patch amount of the center position of the belly region is set to be-3-0 mm, the casting patch amount of the top end is set to be 0mm, the casting patch amount of the bottom end is set to be 0mm, the patch amounts from the center position to the top end are uniformly transited, and the patch amounts from the center position to the bottom end are uniformly transited;

or (3) the patch amount design of the hub casting: the hub comprises a cover box flange at the top, a bottom box flange at the bottom, three blade flanges which mutually form 120 degrees and a spherical surface for connecting the five flanges, the port of each blade flange is provided with a rib plate surface, a motor hole and a plurality of lugs are arranged on the rib plate surface, the patching amount of the end surface of the cover box flange and the motor hole is +14 to +16mm, the patching amount of the end surface of the bottom box flange and the end surface of the blade flange is +11 to +13mm, if the wall thickness of the spherical surface and the rib plate surface is in positive and negative tolerance, the patching amount is 0 without the patching amount, if the wall thickness of the spherical surface and the rib plate surface is in positive and negative tolerance, the patching amount is 1/3 of a tolerance zone, the patching amount of the lug end surface of a lug which needs to be completed by a fitter is 8 to 10mm, the patching amount of the lug end surface of a screw hole on the lug deviated to the edge of the lug is 2 to 3mm, and the patching amount of the lug.

Furthermore, the top of the side flange end surface starts from the top of the spherical surface, the bottom approaches to the bottom of the spherical surface, and the side flange end surface approaches to the vertical state.

Preferably, on either side of the front side and the rear side of the spherical surface, a central angle of the top region on the circular cross section of the side flange end surface is 30 °, a central angle of the upper transition region on the circular cross section of the side flange end surface is 35 °, a central angle of the side parting surface region on the circular cross section of the side flange end surface is 50 °, and a central angle of the lower transition region on the circular cross section of the side flange end surface is 65 °.

Preferably, the patch design of the direct-drive base casting is suitable for power: 1.5MW-6MW, tonnage: and placing the spherical patch of the direct-drive base casting of 6T-50T.

Preferably, the wall thickness of the center part of the belly region of the doubly-fed semi-closed base has the largest tendency to rise, the tendency to rise upwards and downwards is gradually reduced, and the wall thickness rises by 7% -12% during casting.

Preferably, the patch design of the double-fed semi-closed base is suitable for power: 1.5MW-5MW, tonnage: the casting patch of the belly area of the 10T-40T double-fed semi-closed base is placed, and the belly area belongs to the non-machined surface area.

Preferably, considering that the upper end surface of the bottom box flange is easy to generate casting defects and needs to be polished, in the design of the patching amount of the hub casting, the placement patching amount of the upper plane of the bottom box flange is plus 5mm, and the upper plane of the bottom box flange is in transition with the spherical surface around the bottom box flange.

Preferably, the patch design of the hub casting is adapted to the power: 1.5MW-5MW, tonnage: 10T-50T wind power hub.

Preferably, for direct-drive type base castings and/or double-feed type semi-closed base castings, the casting rigidity is further considered to be improved during casting, a sand box is placed in the pit, molding sand is filled in the sand box, the sand box and the wall body of the pit are supported through steel pipes, and a plurality of steel pipes are symmetrically supported around the sand box.

Preferably, for the direct-drive type base casting and/or the doubly-fed type semi-closed base casting, the casting mold rigidity is also considered to be improved during casting, a sand box is placed in the pit, the sand box is filled with molding sand, a tension rod is arranged on the sand box, and two ends of the tension rod are respectively in locking connection with the sand box.

Compared with the prior art, the invention has the advantages that: the application provides a wind power casting low-subsiding-amount casting process, and a product relates to a direct-drive type base, a double-fed type semi-closed base and a hub, the size of a casting can be effectively controlled to exceed the range of dimensional tolerance by optimizing the subsiding amount, the allowance after the subsiding amount is reduced is also reduced, the machining efficiency is improved, and the casting utilization rate of molten iron is improved.

Drawings

Fig. 1 is a front view of a direct drive base casting according to embodiment 1 of the present invention;

FIG. 2 is a top view of a direct drive base casting of example 1 of the present invention;

FIG. 3 is a bottom view of a direct drive base casting of example 1 of the present invention;

fig. 4 is a vertical sectional view of a direct drive base casting according to embodiment 1 of the present invention;

FIG. 5 is a cross-sectional view of FIG. 1;

fig. 6 is a front view of a double-fed type semi-closed base according to embodiment 2 of the present invention;

fig. 7 is a bottom view of a double-fed type semi-closed base according to embodiment 2 of the present invention;

fig. 8 is a left side view of a double-fed type semi-closed base according to embodiment 2 of the present invention;

fig. 9 is a right side view of the doubly-fed type semi-enclosed base of embodiment 2 of the present invention;

FIG. 10 is a cross-sectional view of FIG. 6;

fig. 11 is a casting structure view of a double-fed type semi-closed base according to embodiment 2 of the present invention;

fig. 12 is another casting structure diagram of the doubly-fed type semi-closed base according to embodiment 2 of the present invention;

FIG. 13 is a front elevational view of a hub according to embodiment 3 of the present invention;

FIG. 14 is a left side elevational view of the hub of embodiment 3 of the present invention;

FIG. 15 is a right side elevational view of the hub of embodiment 3 of the present invention;

FIG. 16 is a perspective view of a hub according to embodiment 3 of the present invention;

FIG. 17 is a cross-sectional view of a hub according to embodiment 3 of the present invention;

FIG. 18 is a cross-sectional view AB of FIG. 18;

FIG. 19 is an enlarged view of AZ of FIG. 18;

in the figure, 1 bottom flange end face, 2 inclined plane flange end faces, 3 side flange end faces, 4 belly areas, 5 sand boxes, 6 molding sand, 7 castings, 8 ground faces, 9 pits, 10 steel pipes, 11 pit wall faces, 12 long screws, 13 blade flanges, 14 cover box flanges, 15 bottom box flanges, 16 rib plate faces, 17 lugs and 18 motor holes.

Detailed Description

The present invention will be described in further detail below with reference to the attached drawings, which are illustrative and are not to be construed as limiting the invention. The description of the present embodiment is corresponding to the accompanying drawings, and the description related to the orientation is also based on the description of the accompanying drawings, and should not be construed as limiting the scope of the present invention.

Example 1

The direct-drive base casting has the structural characteristics that the machining surface is less, most of the casting is of a blank structure, the range of the spherical area on the side surface is large, the space of the inner cavity of the casting is large, and the height of the casting is high. The casting with the structure is easily affected by graphitization expansion in the solidification process after the molten iron is filled with the mold, so that a belly region, namely a side parting surface region of the casting is expanded, and the wall thickness is ultra-poor; the idea of solving the side expansion box is changed from a mode of simply improving the rigidity of the casting mould to a mode of increasing the reverse deformation of the mould and improving the rigidity of the casting mould. Need collect mould side dimensional data (use 3D scanning system to detect the mould size, collect the dimensional change condition of mould before and after the production, be exactly the dimensional change of mould itself), sand mould data (the molding sand is the material that forms the casting mould, form external mold and psammitolite after the molding sand sclerosis, through taking a sample to the molding sand, the laboratory is tested, detect bending strength, the bending strength of molding sand is a major factor that influences the casting mould rigidity), foundry goods data (the foundry goods of producing uses 3D scanning system to carry out the size detection), data tracking through many products, summarize foundry goods deflection law: combining the size of the mold, under the condition of the same strength of the molding sand, the wall thickness of a spherical area, namely a side parting surface area, of the middle section of the direct-drive type base casting is increased by about 6-10%, and the patching quantity of the direct-drive type base casting is designed according to the deformation rule.

As shown in fig. 1-5, the direct-drive base casting comprises a spherical surface, a bottom flange end face 1, an inclined flange end face 2 and a side flange end face 3 are arranged on the spherical surface, the inclined flange end face 2 and the side flange end face 3 are respectively positioned at the left side and the right side of the spherical surface, the front side and the rear side of the spherical surface are respectively and sequentially divided into a lower transition area, a side parting surface area, an upper transition area and a top area from bottom to top, wherein the side parting surface area corresponds to a middle section spherical area of the spherical surface with 6% -10% of casting wall thickness expansion, as shown in the figure, the top of the side flange end face 3 starts from the top of the spherical. On any one of the front side and the rear side of the spherical surface, the central angle of the top region on the circular section of the side flange end surface 3 is 30 degrees, the central angle of the upper transition region on the circular section of the side flange end surface is 35 degrees, the central angle of the side parting surface region on the circular section of the side flange end surface 3 is 50 degrees, and the central angle of the lower transition region on the circular section of the side flange end surface 3 is 65 degrees.

The patching quantity corresponding to the side parting surface area is 0, the patching quantity of the lower transition area is gradually reduced within the range of + 2-0 from top to bottom, the patching quantity of the upper transition area is gradually reduced within the range of + 3-0 from top to bottom, and the patching quantity of the top area is 3 mm.

The base is generally the three-box molding, the wall thickness of top is the same easy super poor after the mould assembling, the regional correction amount of current process design top is 3mm in advance, because there is the uncertainty of casting defect in the top region, place the regional integrated into one piece of correction amount and make out during preparation mould, if follow-up mould repair will make up the correction amount and get rid of the work load very big, at present just make the mould time the correction amount do not make earlier, paste alone and go, convenient follow-up removal, see that the back wall thickness condition of foundry goods is come out and whether consider and get rid of.

The specification range of the direct-drive type base adapted by the patching quantity scheme is as follows: 1.5MW-6MW, tonnage: 6T-50T.

Example 2

As shown in fig. 6-10, the typical casting of the doubly-fed semi-closed base has the structural characteristics that the casting machining surface is less, the casting is wholly wrapped by a flat web except a yaw hole and a plurality of through holes and comprises a bottom flange and a top flange, an arc surface, namely a belly region 4, is formed downwards and inwards from the end surface of the top flange, the casting cost is considered during the casting process design of the base, the pouring system is simple in design, the slag inclusion risk is high, slag is prevented from being accumulated on a plane in order to facilitate slag discharge, the base is generally designed to be erected, namely the base is erected, and the bottom flange and the top flange are positioned on the left side and the right side in the transverse direction. The vertical construction can effectively improve the utilization rate of the field besides reducing the cost and slag inclusion, but the vertical construction has the problems that the quantity of mud cores is large, a belly region (cambered surface) is influenced by graphitization expansion, the wall thickness is extremely easy to be out of tolerance and the like; the idea of solving the side expansion box is to increase the mould reverse deformation amount for casting besides simply improving the casting mould rigidity. Therefore, collect mould side dimensional data (use 3D scanning system to detect the mould size, collect the dimensional change condition of mould before and after production, be exactly the dimensional change of mould itself), sand mould data (the molding sand is the material that forms the casting mould, form external mold and psammitolite after the molding sand hardens, through taking a sample to the molding sand, the laboratory is tested, detect bending strength, the bending strength of molding sand is a major factor that influences the casting mould rigidity), foundry goods data (the foundry goods that produces uses 3D scanning system to carry out the size detection), data tracking through many products, summarize foundry goods deflection law: under the condition of the same molding sand strength, the wall thickness of a non-machined surface area, namely a belly area, of the double-fed semi-closed base casting rises by about 7% -12%, the deformation rule is combined, the correction quantity of the non-machined surface area is made to be 3mm, namely the correction quantity of the 4 central position of the belly area is set to be-3 mm, the casting correction quantity of the top end of the belly area is placed to be 0mm, the casting correction quantity of the bottom end is placed to be 0mm, the correction quantity from the central position to the top end is uniformly transited, and the correction quantity from the central position to the bottom end is uniformly transited.

The specification of the double-fed base adapted to the subsidy amount design scheme is as follows: 1.5MW-5MW, tonnage: between 10T and 40T.

The method for improving the rigidity of the casting mould can be a steel pipe pushing method: the sand box is placed in the pit, the sand box is filled with molding sand, and the two sides of the sand box are supported by the steel pipes and the wall body of the pit, so that the rigidity of the sand box is ensured during pouring, as shown in fig. 11. Or the flask is supported by the long screw rod, the long screw rod is transversely arranged, and two ends of the long screw rod are respectively locked with the left side wall and the right side wall of the flask, as shown in figure 12.

Example 3

Wind-power class wheel hub structure is all more similar, generally includes the lid case flange at top, the end case flange of bottom, three each other become 120 blade flanges and connect the sphere of these five flanges, and the port of each blade flange has the muscle face, sets up motor hole and a plurality of lug on the muscle face. The spherical surface box expansion tendency is smaller than that of a wind power base casting, the work of reducing the gross-to-net ratio is mainly started from the aspect of reducing machining allowance, the machining surfaces of hub castings mainly comprise three blade flanges, a cover box flange and a bottom box flange, along with the years of exploration, the die precision is improved, the positioning design of various cores is reasonable, the operation method is improved, various size control methods are provided with large positioning, pre-allocation and various special clamping plates to ensure the size precision of the castings, excessive machining allowance is increased, and the utilization rate of molten iron is reduced. The hub patching amount is optimized, the patching amounts of the flange end face of the cover box and the motor hole are controlled to be about 12mm except 15mm, and the patching amounts of other processing surface areas are controlled to be about 12 mm. If the wall thickness of the spherical surface and the surface of the rib plate can adopt positive and negative tolerance, no correction amount is released; if the tolerance is positive, the correction amount is 1/3 of a tolerance zone, the method is executed, the correction amount of the wall thickness of the spherical surface is +2mm, the correction amount of the wall thickness in the rib plate surface is +2mm, in addition, the upper end surface of the bottom box flange is easy to generate casting defects and needs to be polished, and therefore the correction amount of the upper plane of the bottom box flange is set to be +5mm, and the transition is made with the peripheral spherical surface. In addition, for the lug on the rib plate surface, the lug is an independent boss higher than the casting body, the patching quantity of the lug end surface is appropriately placed by about 8-10 mm which needs to be placed by a bench worker, the correction quantity of the screw hole center close to the lug edge is 2-3mm, and the rest is not placed.

The specification range of the wind power hub casting adapted by the subsidy quantity design scheme is as follows: 1.5MW-5MW, tonnage: between 10T and 50T.

In addition to the above embodiments, the present invention also includes other embodiments, and any technical solutions formed by equivalent transformation or equivalent replacement should fall within the scope of the claims of the present invention.