气冲造型湿型砂的性能优化
摘要
用湿型砂气冲造型生产铸钢件是一种经济而有效的生产方式,铁路货车用铸钢件批量大,钢种品种少,易于组织连续生产。湿型砂混制简单,成型后不需要任何处理,下芯后可浇注。它和射压、静压等高压造型同属高密度造型。它是以压缩空气为动力,瞬间成型。它与普通机器造型相比,由于砂型的湿压强度高,硬度分布均匀,因而获得铸件的尺寸精确、表面光洁、组织致密、机械性能提高、生产率高、劳动条件改善。气冲造型的硬度分布比一般的高压造型更合理,砂型中靠近模样的部分硬度高,背面的硬度低,砂型的退让性好。另外,它的设备简单,比较灵活,动力价格低廉。因此,湿型砂的开发和应用前景非常广阔。
型砂对铸件的质量影响很大, 通过此次课题研究,把湿型砂的性能做进一步的改进优化,来充分发挥气冲造型的优越性,减少铸件的气孔、粘砂、冲砂、胀箱、裂纹、夹砂、变形等铸造缺陷。在整个课题的研究过程中,准备分两步进行,首先进行探索性实验,初步确定要达到的型砂性能指标,然后在型砂组成中分别加入不同量的新砂、膨润土、淀粉、MD 粉,检测型砂的性能,确定附加物的大致成分。第二步是在探索性实验基础上做正交实验,优选配方。
本研究主要探讨了用气冲造型湿型砂来生产铁路钩缓铸钢件,从型砂的配方和型砂系统的控制等几个方面来优化其性能。高密度湿型砂对原材料的质量要求很高。首先通过对几种原砂、膨润土、粮食附加物的基本性能的检测,找出它们自身的理化性能的不同对型砂工艺性能的影响,相互组分之间的影响因素,系统的对原材料、型砂的性能进行实验,完成原材料的优化。其中重点检测了原砂的石英含量,粘土的液限值,并通过液限值确定膨润土的适宜活化量,测定热湿拉强度、湿压强度,并绘制相关的影响曲线,用差热分析曲线分析膨润土的复用性能,从中积累了大量的实验数据。另外在选用湿型砂原材料时,还充分考虑了国内原材料的质量及交通运输等多方面因素,参考了国内外高压造型线使用情况,立足于国内原材料以及对型砂基本性能的要求,试验湿型砂气冲造型的型砂配方,完成型砂的配比优化。并结合我厂的情况,试验研究了各种材料复合后的复合膨润土,以保证原材料混和均匀,克服原先加料分层现象,造成强度不均,缺陷严重,来提高湿型砂
It is an economical and effective method to produce steel castings with green-sand air impact molding technology. The steel castings for rolling stock are needed in great batch and few variety, thus it is easy to manage production in series. Green-sand is easy to prepare by mixing and needs no treatments after formation. It can be poured immediately after core setting. Green-sand belongs to high density molding as shoot squeeze and static pressure such high pressure molding. It is powered by compressing air to mold in a moment. Comparing with the traditional molding technology, the sand mold is with a high moistening pressure and a even distribution of hardness. Thus the castings from green sand mold is with precise dimension, smooth surface and compaction organization. The mechanical behavior and the production rate are improved. The working conditions are improved. The air flush molding has a better distribution of hardness than ordinary high pressure molding. The part near to model is with a high hardness and the back part is with a low hardness. The sand mold is with a good conceding performance. What more, the green sand mold needs simple equipment and is very flexible to operate. The power price is very low. Thus, the future of the development and application of green-sand mold is very prosperous.
Molding sand is very important to casting’s quality. Through the research on the specific object, the characters of green-sand is expected to be improved. The research paper intends to develop the advantages of air flush molding and reduce the casting defects: blow hole, sand fusion, sand cut, swelling, sand inclusion and deforming. The whole research is divided to 2 parts: a researching test shall be performed at first, in order to confirm basically the feature parametes that the molding sand should achieve. Then, add respectively new sand, bentonite, amylum, MD powder, and check the features for the molding sand to finalize the element of the additives added. Secondly, on basis of exploring experiment, do the normal experiment to select the chemical composition.
This research mainly explores the production of steel castings with air flush molding green sand and the improvement of its character from the molding sand recipe and mold sand system control. The high density green-sand molding has a high requirement for materials quality. First find the different influence brought by their physical and chemical characters to the molding sand workmanship character by inspecting the characters of some kinds of original sand, betonies, and grain attachment. The influential factors of mutual component shall be found. The original materials and molding sand character shall be systematically experimented to finish the improvement of original material. Particularly the quartz content, the liquid limit of clay soil shall be inspected. By inspecting the liquid limit, the proper activation amount is defined. The moist heat pulling intensity and the moist pressure intensity shall be measured and the influence curve line will be drawn. The multiple-use character of betonies will be analyzed with differential thermal analysis curve, in result of great experiment data and experiment have been accumulated. In additional, it is found that when selecting the green-sand materials, the domestic material quality and transportation should be considered. The domestic high pressure molding application situation will also be fully considered. On the basis of domestic material and the requirements of molding sand, the experiments of green-sand air flush molding recipe will be made and the improvements of molding sand match will be finished. Associated with the situation of my manufacture, the general character of green-sand is improved by researching the compound betonies mixed with variety of materials to ensure that the materials is mixed evenly and eliminate the classification of feeding which causes the uneven hardness distribution and serious defects. Second, the effective management and control of molding sand system will be improved to improve the molding sand’character. Finally, by comparing the pouring casting substances, the casting defects such as sand fusion, sand cut, and sand inclusion are solved and the quality of products is improved.
型砂对铸件的质量影响很大, 通过此次课题研究,把湿型砂的性能做进一步的改进优化,来充分发挥气冲造型的优越性,减少铸件的气孔、粘砂、冲砂、胀箱、裂纹、夹砂、变形等铸造缺陷。在整个课题的研究过程中,准备分两步进行,首先进行探索性实验,初步确定要达到的型砂性能指标,然后在型砂组成中分别加入不同量的新砂、膨润土、淀粉、MD 粉,检测型砂的性能,确定附加物的大致成分。第二步是在探索性实验基础上做正交实验,优选配方。
本研究主要探讨了用气冲造型湿型砂来生产铁路钩缓铸钢件,从型砂的配方和型砂系统的控制等几个方面来优化其性能。高密度湿型砂对原材料的质量要求很高。首先通过对几种原砂、膨润土、粮食附加物的基本性能的检测,找出它们自身的理化性能的不同对型砂工艺性能的影响,相互组分之间的影响因素,系统的对原材料、型砂的性能进行实验,完成原材料的优化。其中重点检测了原砂的石英含量,粘土的液限值,并通过液限值确定膨润土的适宜活化量,测定热湿拉强度、湿压强度,并绘制相关的影响曲线,用差热分析曲线分析膨润土的复用性能,从中积累了大量的实验数据。另外在选用湿型砂原材料时,还充分考虑了国内原材料的质量及交通运输等多方面因素,参考了国内外高压造型线使用情况,立足于国内原材料以及对型砂基本性能的要求,试验湿型砂气冲造型的型砂配方,完成型砂的配比优化。并结合我厂的情况,试验研究了各种材料复合后的复合膨润土,以保证原材料混和均匀,克服原先加料分层现象,造成强度不均,缺陷严重,来提高湿型砂
It is an economical and effective method to produce steel castings with green-sand air impact molding technology. The steel castings for rolling stock are needed in great batch and few variety, thus it is easy to manage production in series. Green-sand is easy to prepare by mixing and needs no treatments after formation. It can be poured immediately after core setting. Green-sand belongs to high density molding as shoot squeeze and static pressure such high pressure molding. It is powered by compressing air to mold in a moment. Comparing with the traditional molding technology, the sand mold is with a high moistening pressure and a even distribution of hardness. Thus the castings from green sand mold is with precise dimension, smooth surface and compaction organization. The mechanical behavior and the production rate are improved. The working conditions are improved. The air flush molding has a better distribution of hardness than ordinary high pressure molding. The part near to model is with a high hardness and the back part is with a low hardness. The sand mold is with a good conceding performance. What more, the green sand mold needs simple equipment and is very flexible to operate. The power price is very low. Thus, the future of the development and application of green-sand mold is very prosperous.
Molding sand is very important to casting’s quality. Through the research on the specific object, the characters of green-sand is expected to be improved. The research paper intends to develop the advantages of air flush molding and reduce the casting defects: blow hole, sand fusion, sand cut, swelling, sand inclusion and deforming. The whole research is divided to 2 parts: a researching test shall be performed at first, in order to confirm basically the feature parametes that the molding sand should achieve. Then, add respectively new sand, bentonite, amylum, MD powder, and check the features for the molding sand to finalize the element of the additives added. Secondly, on basis of exploring experiment, do the normal experiment to select the chemical composition.
This research mainly explores the production of steel castings with air flush molding green sand and the improvement of its character from the molding sand recipe and mold sand system control. The high density green-sand molding has a high requirement for materials quality. First find the different influence brought by their physical and chemical characters to the molding sand workmanship character by inspecting the characters of some kinds of original sand, betonies, and grain attachment. The influential factors of mutual component shall be found. The original materials and molding sand character shall be systematically experimented to finish the improvement of original material. Particularly the quartz content, the liquid limit of clay soil shall be inspected. By inspecting the liquid limit, the proper activation amount is defined. The moist heat pulling intensity and the moist pressure intensity shall be measured and the influence curve line will be drawn. The multiple-use character of betonies will be analyzed with differential thermal analysis curve, in result of great experiment data and experiment have been accumulated. In additional, it is found that when selecting the green-sand materials, the domestic material quality and transportation should be considered. The domestic high pressure molding application situation will also be fully considered. On the basis of domestic material and the requirements of molding sand, the experiments of green-sand air flush molding recipe will be made and the improvements of molding sand match will be finished. Associated with the situation of my manufacture, the general character of green-sand is improved by researching the compound betonies mixed with variety of materials to ensure that the materials is mixed evenly and eliminate the classification of feeding which causes the uneven hardness distribution and serious defects. Second, the effective management and control of molding sand system will be improved to improve the molding sand’character. Finally, by comparing the pouring casting substances, the casting defects such as sand fusion, sand cut, and sand inclusion are solved and the quality of products is improved.
引文
1 贾宝林. 国外几家铸机公司的湿型砂造型技术简介. 铸造,1996,(10):40~41
2 石晶玉,何镇明,王强. 设计和应用绿色粘结剂. 中国机械工程,1999,10(7):816
3 陈其刚,王志刚,贾非. 用湿型砂冲击造型生产铸钢件. 机车车辆工艺,1995,(5):16~18
4 孟樊芬主编. 造型材料. 哈尔滨:哈尔滨工业大学出版社,1996:31~32
5 D.Boenish,湿砂造型冲击紧实的特点. 译自49 届国际铸造会议文,1980,32
6 李新亚. 铸造行业国内外生产技术现状及发展方向. 铸造,1999,(9):12
7 权尚吉,夏福权. 潮模砂在阀门铸钢件上的应用. 铸造,1997,(1):24~25
8 田广荣,赵丽.铸造中粘土湿型砂的成因及预防. 林业机械,1995,(4):31
9 F.Hofmann. Training Seminar on Clay Bonded Moulding Sands . Cast Metals Series,1985,(9):25
10 徐正达. 提高湿型砂抗粘砂能力的措施. 铸造技术,1996,(5):20~22
11 Groham. Sand Testing-A Guide to Aystem Ddsign. Cast ,1975:132~134
12 F.Hofmann. StrutualChanges of Citlulating Foudry System Sands. George FischerLmited. GA,1982,4:705
13 GF. Test Report on Moulding Materials by the First Automobile Works. Modern Casting,1986,(2):6
14 于震宗. 原砂的颗粒组成. 造型材料,1984,(3):25~30
15 昆明工学院主编. 造型材料. 北京:云南人民出版社,1983:26~38
16 AFS:High Pressare Moulding. Istedition,1972:115
17 于震宗,黄天佑. 膨润土的质量与检测. 北京:北京市机械局技术开发研究所,1983:1~2
18 黄天佑. 我国砂型铸造工艺与造型材料技术发展回顾. 铸造,2002,(5):257~258
19 朱鼎荪. 为适应引进造型线提出的粘土砂性能改造措施. 铸造设备研究, 1997,(3):9~13
20 W.Meger,Giesserei Rundschuu. Cast Metals Series,1972,19:66~69
21 D.Boenischs,W.Patterson.Research of Green Sand. Modern Casting,1982:170~174
22 二国二郎编. 王徽青译.淀粉科学手册. 北京:轻工业出版社,1990:25~27
23 周杰,徐庆柏. α淀粉及其在湿型砂中的应用.安徽工学院学报,1996,(4): 1~6
24 于震宗. 湿型砂用α淀粉的研究. 铸造,1988,(1): 7~8
25 王庆顺. 湿型砂的抗夹砂性能实验分析. 铸造,1998,(12):44~48
26 F hofman:Relevant Compositioned Properties of Green System Moulding Sand for Automatic Including Impact Moulding. Modern Casting,1983:53
27 李传械. 铸造工程师手册. 北京:机械工业出版社,2003:405~407
28 W.Patterson D.Boenischs:Giesserei Techn-Wiss. Beih. 13.1961,157~193
29 内村胜次. 快速检测技术的研究和发展. 铸物,1985,(10):647~652
30 黄祖裘. 湿型砂性能的快速检测. 铸造机械,1984,(2):21~25
31 李建中,陆杰. 型砂紧实率快速检测方法的研究与实现. 制造业自动化,2000,(5):54~55
32 陆文周,肖锋. 型砂综和性能计算机检测装置的研究. 铸造设备研究,1997,(6):29~32
33 黄天佑. THMC 水分自动控制系统. 中国铸造装备与技术,1997,(5):15~16
34 袁永健. 混砂机配料称量及型砂水分在线自动检测装置. 中国铸造装备与技术,2000,(5):48~50
35 吴成东. 湿型砂辅助材料性能的检测方法. 造型材料,1990,(3):35~39
36 John Sch oen. Mod. Cast,1990,80(6):25
37 董静薇,李大勇.湿型粘土砂质量自动检测与控制技术述评. 铸造,2003,(5):314~315
38 李大勇. 双电源激励法快速测定湿型砂有效粘土含量实验研究. 哈尔滨理工大学学报,1996,(5):16~18
39 PediciuiLJ. Testing Procedures Significant to Casting Quality. Modern Casting, 1990,(4):39~41
40 余笃武. 湿型砂韧性与破碎指数测试方法的研究. 造型材料,1990,(4):49~53
41 Dirter H W and Graham AL.Sand Toughness. AFS Transactions,1972,80:441
42 Grahan.AL,Praski.PRM and Eduards D H. Measuring Friability of Molding Sand Testing Equipment. AFS Transactions,1997,87:454~458
43 谢祖锡. 湿型砂检测的概况及新发展. 铸造设备研究,2000,(1):5~7
44 Williams,M.J.Knight,J.Beale. 扬正山译. 国际上对湿型砂控制的今后展望. 国外造型材料,1978,(3):29~35
45 Gregor.Brummer.樊养柏译. 膨润土砂的活化.盐化.解活化和K+的固定. 造型材料,1999,23(1):37~38
46 Eicke Brummer Werner Lautzus.芯砂对膨润土回用砂的影响. 国外现代铸造.上海科学技术文献出版社,1979,(8):34~37
47 刘瑞玲. 混砂工艺对粘土湿型砂性能的影响. 河北科技大学学报,2002,(3):52~55
48 王维倜. 粘土砂处理的再认识. 铸造,2001,(4):9~13
49 符刚. 机车车辆制造技术的现状和展望综述. 机车车辆工艺,2002,(4):2~3
50 McCombe,Recent Trends in Green-sand Moulding Machine Design. Foundry Trade Journal,1992,(5):17
51 L.Kotzin,Metal Casting and Moulding Process. Cast Metals Series,1981,(6):28
52 Dietmar Boenish 湿型造型冲击紧实的特点. 柴油机设计与制造. 铸造专刊上柴编,1976,(4):12~15
2 石晶玉,何镇明,王强. 设计和应用绿色粘结剂. 中国机械工程,1999,10(7):816
3 陈其刚,王志刚,贾非. 用湿型砂冲击造型生产铸钢件. 机车车辆工艺,1995,(5):16~18
4 孟樊芬主编. 造型材料. 哈尔滨:哈尔滨工业大学出版社,1996:31~32
5 D.Boenish,湿砂造型冲击紧实的特点. 译自49 届国际铸造会议文,1980,32
6 李新亚. 铸造行业国内外生产技术现状及发展方向. 铸造,1999,(9):12
7 权尚吉,夏福权. 潮模砂在阀门铸钢件上的应用. 铸造,1997,(1):24~25
8 田广荣,赵丽.铸造中粘土湿型砂的成因及预防. 林业机械,1995,(4):31
9 F.Hofmann. Training Seminar on Clay Bonded Moulding Sands . Cast Metals Series,1985,(9):25
10 徐正达. 提高湿型砂抗粘砂能力的措施. 铸造技术,1996,(5):20~22
11 Groham. Sand Testing-A Guide to Aystem Ddsign. Cast ,1975:132~134
12 F.Hofmann. StrutualChanges of Citlulating Foudry System Sands. George FischerLmited. GA,1982,4:705
13 GF. Test Report on Moulding Materials by the First Automobile Works. Modern Casting,1986,(2):6
14 于震宗. 原砂的颗粒组成. 造型材料,1984,(3):25~30
15 昆明工学院主编. 造型材料. 北京:云南人民出版社,1983:26~38
16 AFS:High Pressare Moulding. Istedition,1972:115
17 于震宗,黄天佑. 膨润土的质量与检测. 北京:北京市机械局技术开发研究所,1983:1~2
18 黄天佑. 我国砂型铸造工艺与造型材料技术发展回顾. 铸造,2002,(5):257~258
19 朱鼎荪. 为适应引进造型线提出的粘土砂性能改造措施. 铸造设备研究, 1997,(3):9~13
20 W.Meger,Giesserei Rundschuu. Cast Metals Series,1972,19:66~69
21 D.Boenischs,W.Patterson.Research of Green Sand. Modern Casting,1982:170~174
22 二国二郎编. 王徽青译.淀粉科学手册. 北京:轻工业出版社,1990:25~27
23 周杰,徐庆柏. α淀粉及其在湿型砂中的应用.安徽工学院学报,1996,(4): 1~6
24 于震宗. 湿型砂用α淀粉的研究. 铸造,1988,(1): 7~8
25 王庆顺. 湿型砂的抗夹砂性能实验分析. 铸造,1998,(12):44~48
26 F hofman:Relevant Compositioned Properties of Green System Moulding Sand for Automatic Including Impact Moulding. Modern Casting,1983:53
27 李传械. 铸造工程师手册. 北京:机械工业出版社,2003:405~407
28 W.Patterson D.Boenischs:Giesserei Techn-Wiss. Beih. 13.1961,157~193
29 内村胜次. 快速检测技术的研究和发展. 铸物,1985,(10):647~652
30 黄祖裘. 湿型砂性能的快速检测. 铸造机械,1984,(2):21~25
31 李建中,陆杰. 型砂紧实率快速检测方法的研究与实现. 制造业自动化,2000,(5):54~55
32 陆文周,肖锋. 型砂综和性能计算机检测装置的研究. 铸造设备研究,1997,(6):29~32
33 黄天佑. THMC 水分自动控制系统. 中国铸造装备与技术,1997,(5):15~16
34 袁永健. 混砂机配料称量及型砂水分在线自动检测装置. 中国铸造装备与技术,2000,(5):48~50
35 吴成东. 湿型砂辅助材料性能的检测方法. 造型材料,1990,(3):35~39
36 John Sch oen. Mod. Cast,1990,80(6):25
37 董静薇,李大勇.湿型粘土砂质量自动检测与控制技术述评. 铸造,2003,(5):314~315
38 李大勇. 双电源激励法快速测定湿型砂有效粘土含量实验研究. 哈尔滨理工大学学报,1996,(5):16~18
39 PediciuiLJ. Testing Procedures Significant to Casting Quality. Modern Casting, 1990,(4):39~41
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