阅读说明：本技术 一种采用壳型铸造160km机车蠕墨铸铁盘体的铸造工艺 (Casting process for casting 160KM locomotive vermicular graphite cast iron disc body by adopting shell mold ) 是由 温文林 田慧 付俊岭 冯奇红 刘春晖 张永芳 于 2021-01-22 设计创作，主要内容包括：本发明涉及一种采用壳型铸造160KM机车蠕墨铸铁盘体的铸造工艺,该方法通过制壳机射砂得到厚度为15-20mm的上壳体、下壳体、芯子和浇口杯,然后把芯放入下壳,用粘结剂粘结上、下壳和浇口杯,直接把组合壳体水平放入砂箱,用铁砂将其埋住,浇注铁水铸出盘体零件,有效提高了铸件质量,100％达到蠕墨铸铁RUT400材质要求,与消失模工艺相比,工艺出品率由75％提高到90％以上,消除盘内部缩松、缩孔,铸件成品率由60％达到98％,生产效率提高了3倍,用人由每班15人减少为6人、模具成本由20万降为5万,该方法成本低,而且简单易行,适合绝大多数企业使用。(The invention relates to a casting process for casting a 160KM locomotive vermicular cast iron disc body by adopting a shell mould, the method comprises the steps of obtaining an upper shell, a lower shell, a core and a pouring cup with the thickness of 15-20mm by sand shooting of a shell making machine, then the core is placed into the lower shell, the upper shell, the lower shell and the pouring cup are bonded by using an adhesive, the combined shell is directly and horizontally placed into a sand box and buried by using iron sand, and molten iron is poured to cast the parts of the plate body, so that the quality of the cast is effectively improved, the 100 percent meets the requirement of the vermicular cast iron RUT400 material, compared with the lost foam process, the process yield is improved to more than 90 percent from 75 percent, shrinkage porosity and shrinkage cavity inside the disc are eliminated, the casting yield is up to 98 percent from 60 percent, the production efficiency is improved by 3 times, the number of workers is reduced from 6 to 15 per shift, the cost of the mold is reduced from 20 to 5 thousands, and the method has low cost and is simple and easy to implement and suitable for most enterprises.)

1. A casting process for casting a 160KM locomotive vermicular cast iron disc body by adopting a shell mold is characterized by comprising the following steps of:

(1) designing and manufacturing a set of lower shell model completely consistent with the shape of the plate body;

(2) designing and manufacturing a set of upper shell model completely consistent with the shape of the plate body, wherein the clearance between the upper shell model and the lower shell model is 15-20mm when the upper shell model and the lower shell model are matched;

(3) designing a set of core models matched with the upper shell model and the lower shell model;

(4) respectively fixing the lower molds of the lower shell mold and the core mold on a fixed plate of a movable vehicle of a shell making machine to be used as movable molds, respectively fixing the upper molds of the upper shell mold and the core mold on the upper parts of the corresponding shell making machines to be used as fixed molds, closing and clamping the corresponding upper and lower molds, heating to 170 ℃ and 180 ℃, clamping the sand shooting plate in place, then shooting sand, curing for 120 seconds, and simultaneously demoulding the pressure head and the lower molds of the lower shell mold/core mold in a downward way;

(5) the lower mold of the lower shell model/core model descends in place and then is stripped, and then the lower shell model/core model horizontally moves forwards to obtain two upper and lower shells with the thickness of 15-20mm, a pouring cup and a core;

(6) polishing the core, placing the core into a lower shell, bonding an upper shell and a lower shell and a pouring cup by using a high-temperature binder, burying the combined shell into a sandbox by using iron sand in a horizontal mode, and waiting for pouring;

(7) the raw materials are sequentially added into a medium-frequency electric furnace according to a mixture list for heating and smelting, and the tapping temperature of the molten iron is 1555 and 1565 ℃;

(8) carrying out vermicular treatment on the molten iron by adopting a flushing method;

(9) pouring the molten iron after the vermicular treatment for 10 minutes at 1460 ℃ of 1450, thus obtaining the required disk body blank part, and opening the box after heat preservation for 15 minutes to take out the casting.

2. The casting process of claim 1, wherein the designing and manufacturing of the lower shell model having a shape identical to that of the disc body, the designing and manufacturing of the upper shell model having a shape identical to that of the disc body and the designing of the core model matching with the upper and lower shell models comprise designing of a sand shooting plate, a pressure head and a top plate required for manufacturing of the tool mold of the disc body.

3. The casting process for casting a 160KM locomotive vermicular cast iron disc body by using a shell mold as claimed in claim 1, wherein the model of the shell making machine is JFSS1080 homemade core making machine.

4. The casting process for casting a 160KM locomotive vermicular cast iron disc body according to claim 1, wherein the chemical compositions of the tapping molten iron during casting are as follows (weight percentage): 3.7 to 3.8 percent of C, 1.65 to 1.75 percent of Si, 0.7 to 0.8 percent of Mn0.7, 0.7 to 0.8 percent of Cu and 0.3 to 0.35 percent of Mo.

5. The casting process for casting a 160KM locomotive vermicular cast iron disc body according to claim 1, wherein the Ti content in the raw molten iron is (weight percentage): 0.02-0.04%.

6. The casting process for casting the 160KM locomotive vermicular cast iron disc body according to claim 1, wherein the vermicular iron inoculant in the ladle is as follows (by weight percent): 0.85 percent; the inoculant in the molten iron during pouring is as follows (weight percentage): 0.15-0.2%.

7. The casting process of a shell mold cast 160KM locomotive vermicular cast iron disc body according to claim 1, wherein the weight control range of the tapping molten iron is as follows: 10 KG.

Technical Field

The invention relates to a casting process of a vermicular cast iron disc body, in particular to a casting process for casting a 160KM locomotive vermicular cast iron disc body by adopting a shell mold.

Background

In the existing industrial production, disc bodies in various shapes are widely applied, the casting process adopted by enterprises in the society at present for producing vermicular cast iron disc bodies is a lost foam casting process, and the process has the following defects in the casting process: 1. the process yield is low and is only 75%; 2. about 20% of the castings have shrinkage porosity and shrinkage cavity inside; the yield of the casting is 60%; 3. the number of people is more than 15 per class; 4. the cost of the die is high; 5. the production efficiency is low, and 10 furnaces are produced in each shift.

Disclosure of Invention

In view of the above, the present invention provides a casting process for casting a 160KM locomotive vermicular cast iron disc body by using a shell mold, wherein disc body parts can be cast in a large scale, with high precision and at low cost by using the shell mold casting process.

In order to achieve the purpose of the invention, the technical scheme is as follows:

the casting process for casting the 160KM locomotive vermicular cast iron disc body by adopting the shell mould comprises the following steps of:

(1) designing and manufacturing a set of lower shell model completely consistent with the shape of the plate body;

(2) designing and manufacturing a set of upper shell model completely consistent with the shape of the plate body, wherein the clearance between the upper shell model and the lower shell model is 15-20mm when the upper shell model and the lower shell model are matched;

(3) designing a set of core models matched with the upper shell model and the lower shell model;

(4) respectively fixing the lower molds of the lower shell mold and the core mold on a fixed plate of a movable vehicle of a shell making machine to be used as movable molds, respectively fixing the upper molds of the upper shell mold and the core mold on the upper parts of the corresponding shell making machines to be used as fixed molds, closing and clamping the corresponding upper and lower molds, heating to 170 ℃ and 180 ℃, clamping the sand shooting plate in place, then shooting sand, curing for 120 seconds, and simultaneously demoulding the pressure head and the lower molds of the lower shell mold/core mold in a downward way;

(5) the lower mold of the lower shell model/core model descends in place and then is stripped, and then the lower shell model/core model horizontally moves forwards to obtain two upper and lower shells with the thickness of 15-20mm, a pouring cup and a core;

(6) polishing the core, placing the core into a lower shell, bonding an upper shell and a lower shell and a pouring cup by using a high-temperature binder, burying the combined shell into a sandbox by using iron sand in a horizontal mode, and waiting for pouring;

(7) the raw materials are sequentially added into a medium-frequency electric furnace according to a mixture list for heating and smelting, and the tapping temperature of the molten iron is 1555 and 1565 ℃;

(8) carrying out vermicular treatment on the molten iron by adopting a flushing method;

(9) pouring the molten iron after the vermicular treatment for 10 minutes at 1460 ℃ of 1450, thus obtaining the required disk body blank part, and opening the box after heat preservation for 15 minutes to take out the casting.

As a further improvement of the invention, the design and manufacture of a set of lower shell model completely consistent with the shape of the plate body, the design and manufacture of a set of upper shell model completely consistent with the shape of the plate body and the design of a set of core model matched with the upper shell model and the lower shell model comprise a sand shooting plate, a pressure head and a top plate required by the design and manufacture of a plate body tooling mold.

As a further improvement of the invention, the shell making machine is a core making machine made by JFSS 1080.

As a further improvement of the invention, the chemical components of the discharged molten iron are as follows (weight percentage): 3.7 to 3.8 percent of C, 1.65 to 1.75 percent of Si, 0.7 to 0.8 percent of Mn0.7, 0.7 to 0.8 percent of Cu and 0.3 to 0.35 percent of Mo.

As a further improvement of the invention, the Ti content in the base iron is as follows (weight percentage): 0.02-0.04%.

As a further improvement of the invention, the ladle is added with a vermicular iron inoculant which comprises the following components in percentage by weight: 0.85 percent; the inoculant in the molten iron during pouring is as follows (weight percentage): 0.15-0.2%.

As a further improvement of the invention, the weight control range of the discharged molten iron is as follows: 10 KG.

The invention has the beneficial effects that: the invention eliminates the defects of shrinkage porosity and shrinkage cavity in the tray body by 100 percent; the internal structure of the tray body is compact, the creep grade reaches more than 70 percent, and the roughness of the casting can reach Ra25 mu m; the yield of the casting reaches 98% from 60%, and the production efficiency is improved by 3 times; the process yield reaches 90%, the number of people used is reduced from 15 people per shift to 6 people, the cost of the die is reduced from 20 ten thousand to 5 ten thousand, and the method is low in cost, simple and easy to operate and suitable for most enterprises.

Drawings

The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:

FIG. 1 is a schematic casting diagram of the present invention.

Detailed Description

It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.

In order to make the technical solutions better understood by those skilled in the art, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application, and it is obvious that the described embodiments are only partial embodiments of the present application, but not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.

The casting process for casting the 160KM locomotive vermicular cast iron disc body by adopting the shell mould comprises the following steps of:

(1) designing and manufacturing a set of lower shell model completely consistent with the shape of the plate body;

(2) designing and manufacturing a set of upper shell model completely consistent with the shape of the plate body, wherein the clearance between the upper shell model and the lower shell model is 15-20mm when the upper shell model and the lower shell model are matched;

(3) designing a set of core models matched with the upper shell model and the lower shell model;

(4) respectively fixing the lower molds of the lower shell mold and the core mold on a fixed plate of a movable vehicle of a shell making machine to be used as movable molds, respectively fixing the upper molds of the upper shell mold and the core mold on the upper parts of the corresponding shell making machines to be used as fixed molds, closing and clamping the corresponding upper and lower molds, heating to 170 ℃ and 180 ℃, clamping the sand shooting plate in place, then shooting sand, curing for 120 seconds, and simultaneously demoulding the pressure head and the lower molds of the lower shell mold/core mold in a downward way;

(5) the lower mold of the lower shell model/core model descends in place and then is stripped, and then the lower shell model/core model horizontally moves forwards to obtain two upper and lower shells with the thickness of 15-20mm, a pouring cup and a core;

(6) polishing the core, placing the core into a lower shell, bonding an upper shell and a lower shell and a pouring cup by using a high-temperature binder, burying the combined shell into a sandbox by using iron sand in a horizontal mode, and waiting for pouring;

(7) the raw materials are sequentially added into a medium-frequency electric furnace according to a mixture list for heating and smelting, and the tapping temperature of the molten iron is 1555 and 1565 ℃;

(8) carrying out vermicular treatment on the molten iron by adopting a flushing method;

(9) pouring the molten iron after the vermicular treatment for 10 minutes at 1460 ℃ of 1450, thus obtaining the required disk body blank part, and opening the box after heat preservation for 15 minutes to take out the casting.

The design, the preparation one set of inferior valve model with the disk body shape identical, the design, the preparation one set of epitheca model with the disk body shape identical and the design one set of core model supporting with upper and lower shell model all including the required shooting plate of design preparation disk body frock mould, pressure head and roof.

The model of the shell making machine is a core making machine made by JFSS 1080.

The chemical components of the discharged molten iron are as follows (weight percentage): 3.7 to 3.8 percent of C, 1.65 to 1.75 percent of Si, 0.7 to 0.8 percent of Mn0.7, 0.7 to 0.8 percent of Cu and 0.3 to 0.35 percent of Mo.

The Ti content in the original molten iron is as follows (weight percentage): 0.02-0.04%.

The ladle is added with a vermicular iron inoculant (weight percentage): 0.85 percent; the inoculant in the molten iron during pouring is as follows (weight percentage): 0.15-0.2%.

The weight control range of the discharged molten iron is as follows: 10 KG.

The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, improvement or combination made within the spirit and principle of the present invention shall fall within the protection scope of the present invention.