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WO2018039852A1 - 一种整体多路阀阀体铸件铸造方法 - Google Patents

一种整体多路阀阀体铸件铸造方法 Download PDF

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Publication number
WO2018039852A1
WO2018039852A1 PCT/CN2016/097127 CN2016097127W WO2018039852A1 WO 2018039852 A1 WO2018039852 A1 WO 2018039852A1 CN 2016097127 W CN2016097127 W CN 2016097127W WO 2018039852 A1 WO2018039852 A1 WO 2018039852A1
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Prior art keywords
core
casting
main
valve body
sand
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French (fr)
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丁先华
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/08—Features with respect to supply of molten metal, e.g. ingates, circular gates, skim gates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/22—Moulds for peculiarly-shaped castings

Definitions

  • the invention relates to the technical field of engineering machinery equipment manufacturing, in particular to a method for casting a whole multi-way valve body casting.
  • the product manufactured by the manufacturing method is a key component of the hydraulic control system of the large excavator, and is the development direction of the hydraulic control system of the large excavator today.
  • An excavator also known as a digging machine, is a earthmoving machine that uses a bucket to excavate materials above or below the surface of the carrier and into the transport vehicle or to the stockyard. From the development of construction machinery in recent years, the development of excavators is relatively fast, and excavators have become one of the most important construction machinery in engineering construction.
  • the hydraulic system consists of hydraulic pumps, control valves, hydraulic cylinders, hydraulic motors, pipelines, fuel tanks, etc.
  • the hydraulic transmission system transmits the power of the engine to the hydraulic pressure through hydraulic pumps.
  • Actuators such as motors and hydraulic cylinders act to drive the work unit to complete various operations.
  • the hydraulic valve is a key component of the hydraulic system.
  • the hydraulic valve structure and precision requirements of the large excavator are very high, especially for some multi-oil valves.
  • the temperature rises rapidly during the working process, and the temperature is too high, resulting in the hydraulic valve not working stably.
  • the amount of wear is large, the pressure fluctuation or shock vibration of the hydraulic system will cause the valve body to leak, and the pressure is ⁇ 35Mpa, the pressure is more likely to leak under the high pressure working condition, the hydraulic valve body casting shrinkage, shrinkage, internal air hole casting, etc.
  • the problem is often a defect in the product, requiring a higher internal tissue compactness and a straightness of the main valve hole casting blank of less than 1.0 mm.
  • the object of the present invention is to provide an integral multi-way valve for the defects existing in the prior art.
  • Casting method of valve body casting, casting valve body casting control main valve hole casting blank straightness is less than or equal to 1.0 mm, ensuring valve hole straightness, solving cast casting shrinkage, shrinkage, internal air hole and other casting defects, especially casting internal micropores
  • the defect is to improve the internal organization compactness to achieve no leakage under the high pressure working condition with rated pressure ⁇ 35Mpa.
  • the present invention provides a method for casting an integral multi-way valve body casting, comprising the following steps:
  • the main core is made of sand, and the steel bar is placed in the main hole of the main core as a core bone, and the vent needle is placed in the mold in sequence, and the vent needle is rotated one turn after the sand is finished, after the main core is shaped, Demolding with a spray release agent;
  • valve body casting using the side thin gate on both sides of the simultaneous casting process, the use of 120mm diameter, 220mm high riser riser, placed special cold iron on the bottom of the shell;
  • the pouring temperature in S7 ranges from 1390 ° C to 1430 ° C
  • the pouring time ranges from 18 s to 25 s
  • the tapping temperature ranges from 1510 ° C to 1530 ° C.
  • stirring is carried out in the riser to prevent the formation of a small molten pool which cannot be complemented, and the feeding effect is achieved.
  • an asbestos cloth having a shrinkage gap of 1.5 mm is placed at the core of all the main holes, and when the casting is expanded, there will be a gap of 1.5 mm to prevent the bending of the main hole, and in combination with the action of the special cold iron,
  • the straightness of the main hole is within 1.0 mm.
  • S2 further includes using a water-based paint, and adding graphite powder to the water-based paint to prepare a paint having a Baume degree range of 35° Bé-42° Bé.
  • the heating temperature of the main core in S2 is 150°C-170°C, the sanding pressure is not less than 0.6MPa, the sanding time is not less than 6s, and the curing time is not less than 120s.
  • an asbestos cloth with a shrinkage gap of 1.5mm is placed at the core of all the main holes. When the casting expands, there will be a gap of 1.5 to prevent the main hole from being bent. The role of iron, thus ensuring the straightness of the main hole is within 1.0mm.
  • the invention provides a method for casting an integral multi-way valve body casting, comprising the following steps:
  • the main core is made of high-strength HAGD290 type sand. During the production, the steel bar is placed in the main hole of the main core as the core bone, and the ventilation needle is placed in the mold in order, and the vent needle is rotated once after the sand is completed. After the main core is shaped, the release agent is used for demolding;
  • valve body casting using the side thin gate on both sides of the simultaneous casting process, using a 120mm diameter, 220mm high riser, placing special cold iron on the bottom of the shell, changing the solidification sequence of molten iron, increasing the solidification speed of the bottom molten iron;
  • the pouring temperature range of the valve body pouring is 1390 ° C - 1430 ° C
  • the pouring time range is 18 s -25 s
  • the tapping temperature range is 1510 ° C - 1530 ° C.
  • stirring is carried out in the riser to prevent the formation of a small molten pool which cannot be complemented, and the feeding effect is achieved.
  • an asbestos cloth having a shrinkage gap of 1.5 mm is placed at the core of all the main holes, and when the casting is expanded, there will be a gap of 1.5 mm to prevent the bending of the main hole, and in combination with the action of the special cold iron,
  • the straightness of the main hole is within 1.0 mm.
  • the preparation of the main core further includes using a HA377 water-based paint, and adding graphite powder to the water-based paint to prepare a paint having a Baume degree range of 35° Bé-42° Bé.
  • the heating temperature in the main core is 150° C.-170° C.
  • the sanding pressure is not less than 0.6 MPa
  • the sanding time is not less than 6 s
  • the curing time is not less than 120 s.
  • an asbestos cloth with a shrinkage gap of 1.5mm is placed at the core of all the main holes. When the casting expands, there will be a gap of 1.5 to prevent the main hole from being bent. The role of iron, thus ensuring the straightness of the main hole is within 1.0mm.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

一种整体多路阀阀体铸件铸造方法，包括以下步骤：准备制芯模具，检查并清理模具；采用型砂制作主芯，主芯定型后，利用喷脱模剂进行脱模；制备小芯，在小芯上钻上排气孔；修除主芯、小芯上的披锋，去除主芯上过渡射嘴；通过砂芯粘制工装固定主芯，先组装一面的小芯，再组装另一面的小芯；将组装好的砂芯安装到壳体内；阀体浇注：采用侧面薄浇口两边同时浇注工艺，使用直径120mm、高220mm的发热冒口，在壳体底面放置专用冷铁。该铸造方法铸造出的整体多路阀阀体铸件的优点是控制主阀孔铸造毛坯直线度小于等于1.0mm，保证阀孔直线度，解决铸件缩孔、缩松、内部气孔等铸造缺陷，特别是铸件内部微孔的缺陷，提高内部组织致密性。

Description

一种整体多路阀阀体铸件铸造方法 技术领域
本发明涉及工程机械设备制造技术领域，具体涉及一种整体多路阀阀体铸件铸造方法。
背景技术
本制造方法制造出的产品是大型挖掘机的液压控制系统关键零部件，是当今大型挖掘机液压控制系统的发展方向。
挖掘机，又称挖掘机械，是用铲斗挖掘高于或低于承机面的物料，并装入运输车辆或卸至堆料场的土方机械。从近几年工程机械的发展来看，挖掘机的发展相对较快，挖掘机已经成为工程建设中最主要的工程机械之一。
现今的大型挖掘机占绝大部分都有液压控制系统，液压系统由液压泵、控制阀、液压缸、液压马达、管路、油箱等组成，液压传动系统通过液压泵将发动机的动力传递给液压马达、液压缸等执行元件，推动工作装置动作，从而完成各种作业。
液压阀是液压系统关键零部件，大型挖掘机的液压阀结构和精度要求非常高，特别是一些多油路的阀，工作过程中温度上升很快，温度过高，造成液压阀不能稳定的工作，并且磨损量大，液压系统的压力脉动或冲击振动的作用下会使阀体泄露，且压力≥35Mpa的高压工作状态下更容易泄漏，液压阀体铸件缩孔、缩松、内部气孔等铸造问题常常会是产品的缺陷，要求更高的内部组织致密性且主阀孔铸造毛坯的直线度小于1.0毫米。
发明内容
本发明的目的是针对现有技术存在的缺陷，提供一种整体多路阀 阀体铸件铸造方法，铸造出的阀体铸件控制主阀孔铸造毛坯直线度小于等于1.0毫米，保证阀孔直线度，解决铸件缩孔、缩松、内部气孔等铸造缺陷，特别铸件内部微孔的缺陷，提高内部组织致密性，以达到额定压力≥35Mpa的高压工作状态下无泄漏。
为了解决上述技术问题，本发明提供了一种整体多路阀阀体铸件铸造方法，包括以下步骤：
S1、准备制芯模具，检查模具并把模具上的污垢清理干净；
S2、采用型砂制作主芯，制作时在主芯的主孔内放置钢筋作为芯骨，并在模具内按顺序摆放通气针，射砂完成后将通气针旋转一圈，主芯定型后，利用喷脱模剂进行脱模；
S3、制备小芯，在小芯上垂直的筋的位置钻上排气孔；
S4、修除主芯、小芯上的披锋，去除主芯上过渡射嘴；
S5、通过砂芯粘制工装固定主芯，先将一面的小芯组装到主芯上，待粘合剂完全凝固后，将组装好的砂芯翻过来再通过砂芯粘制工装固定主芯，再将另一面的小芯组装到主芯上；
S6、准备壳体，将组装好的砂芯安装到壳体内；
S7、阀体浇注：采用侧面薄浇口两边同时浇注工艺，使用直径120mm、高220mm的发热冒口，在壳体底面放置专用冷铁；
S8、阀体成型后，阀体内的主芯和小芯由于高温而溃散，从而形成阀体内腔的流道。
具体地，S7中浇注温度范围为1390℃-1430℃，浇注时间范围为18s-25s，出炉温度范围为1510℃-1530℃。
进一步地，浇注完成后，在冒口中搅拌，进而防止形成无法补足的小熔池，达到补缩效果。
具体地，采用在所有主孔芯头处放置收缩间隙为1.5mm的石棉布，当铸件膨胀时，将有1.5mm的间隙来防止主孔的弯曲，再结合所述专用冷铁的作用，使得主孔的直线度在1.0mm之内。
具体地，S2中还包括使用水基涂料，并在所述水基涂料中加入石墨粉，制成波美度范围为35°Bé-42°Bé的涂料。
S2中制作主芯的加热温度范围为150℃-170℃，射砂压力不小于0.6MPa，射砂时间不少于6s，固化时间不少于120s。
本发明制造方法制造的整体多路阀阀体铸件，具有如下有益效果：
1.采用高强度的HAGD290型号的型砂制芯，使用HA377水基涂料，在主孔内放置直径6.5的钢筋作为芯骨，以增加主孔的抗弯强度，解决砂芯断裂问题；
2.由于铸件流道密集复杂，浇注时热量密集很易产生粘砂等缺陷，采用HA377水基涂料并加入一定量石墨粉作为涂料，涂料的波美度控制在35°Bé-42°Bé，有效的控制了粘砂缺陷；
3.使用直径120mm、高220的发热冒口，底面放置专用冷铁，采用侧面薄浇口两边同时浇注工艺，直接避免了冒口处过热现象，而且能达到很好的散热效果。
4.浇注完成后，使用机械搅拌在冒口中不停的搅拌，防止形成无法补足的小熔池，达到补缩效果；
5.为保证铸件直线度小于1.0mm，采用在所有主孔芯头处放置收缩间隙为1.5mm的石棉布，当铸件膨胀时，将有1.5的间隙来防止主孔的弯曲，再结合底面冷铁的作用，从而保证了主孔的直线度在1.0mm之内。
具体实施方式
下面将结合本发明实施例中的附图，对发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明的实施例，本领域普通技术人员在没有作出创造性劳动的前提下所获得的所有其他实施例，都属于本发明保护的范围。
实施例：
本发明提供了一种整体多路阀阀体铸件铸造方法，包括以下步骤：
S1、准备制芯模具，检查模具并把模具上的污垢清理干净；
S2、采用高强度的HAGD290型号的型砂制作主芯，制作时在主芯的主孔内放置钢筋作为芯骨，并在模具内按顺序摆放通气针，射砂完成后将通气针旋转一圈，主芯定型后，利用喷脱模剂进行脱模；
S3、制备小芯，在小芯上垂直的筋的位置钻上排气孔；
S4、修除主芯、小芯上的披锋，去除主芯上过渡射嘴；
S5、通过砂芯粘制工装固定主芯，先将一面的小芯组装到主芯上，待粘合剂完全凝固后，将组装好的砂芯翻过来再通过砂芯粘制工装固定主芯，再将另一面的小芯组装到主芯上；
S6、准备壳体，将组装好的砂芯安装到壳体内；
S7、阀体浇注：采用侧面薄浇口两边同时浇注工艺，使用直径120mm、高220mm的发热冒口，在壳体底面放置专用冷铁，改变铁水的凝固顺序，增加底部铁水的凝固速度；
S8、阀体成型后，阀体内的主芯和小芯由于高温而溃散，从而形成阀体内腔的流道。
具体地，阀体浇注时浇注温度范围为1390℃-1430℃，浇注时间范围为18s-25s，出炉温度范围为1510℃-1530℃。
进一步地，浇注完成后，在冒口中搅拌，进而防止形成无法补足的小熔池，达到补缩效果。
具体地，采用在所有主孔芯头处放置收缩间隙为1.5mm的石棉布，当铸件膨胀时，将有1.5mm的间隙来防止主孔的弯曲，再结合所述专用冷铁的作用，使得主孔的直线度在1.0mm之内。
具体地，制作主芯中还包括使用HA377水基涂料，并在所述水基涂料中加入石墨粉，制成波美度范围为35°Bé-42°Bé的涂料。
具体地，制作主芯中制作主芯的加热温度范围为150℃-170℃，射砂压力不小于0.6MPa，射砂时间不少于6s，固化时间不少于120s。
本发明制造方法制造的整体多路阀阀体铸件，具有如下有益效果：
1.采用高强度的HAGD290型号的型砂制芯，使用HA377水基涂料，在主孔内放置直径6.5的钢筋作为芯骨，以增加主孔的抗弯强度，解决砂芯断裂问题；
2.由于铸件流道密集复杂，浇注时热量密集很易产生粘砂等缺陷，采用HA377水基涂料并加入一定量石墨粉作为涂料，涂料的波美度控制在35°Bé-42°Bé，有效的控制了粘砂缺陷；
3.使用直径120mm、高220的发热冒口，底面放置专用冷铁，采用侧面薄浇口两边同时浇注工艺，直接避免了冒口处过热现象，而且能达到很好的散热效果。
4.浇注完成后，使用机械搅拌在冒口中不停的搅拌，防止形成无法补足的小熔池，达到补缩效果；
5.为保证铸件直线度小于1.0mm，采用在所有主孔芯头处放置收缩间隙为1.5mm的石棉布，当铸件膨胀时，将有1.5的间隙来防止主孔的弯曲，再结合底面冷铁的作用，从而保证了主孔的直线度在1.0mm之内。
以上所揭露的仅为本发明几种较佳实施例而已，当然不能以此来限定本发明之权利范围，因此依本发明权利要求所作的等同变化，仍属本发明所涵盖的范围。

Claims (6)

  1. 一种整体多路阀阀体铸件铸造方法，其特征在于，包括以下步骤：
    S1、准备制芯模具，检查模具并把模具上的污垢清理干净；
    S2、采用型砂制作主芯，制作时在主芯的主孔内放置钢筋作为芯骨，并在模具内按顺序摆放通气针，射砂完成后将通气针旋转一圈，主芯定型后，利用喷脱模剂进行脱模；
    S3、制备小芯，在小芯上垂直的筋的位置钻上排气孔；
    S4、修除主芯、小芯上的披锋，去除主芯上过渡射嘴；
    S5、通过砂芯粘制工装固定主芯，先将一面的小芯组装到主芯上，待粘合剂完全凝固后，将组装好的砂芯翻过来再通过砂芯粘制工装固定主芯，再将另一面的小芯组装到主芯上；
    S6、准备壳体，将组装好的砂芯安装到壳体内；
    S7、阀体浇注：采用侧面薄浇口两边同时浇注工艺，使用直径120mm、高220mm的发热冒口，在壳体底面放置专用冷铁；
    S8、阀体成型后，阀体内的主芯和小芯由于高温而溃散，从而形成阀体内腔的流道。
  2. 根据权利要求1所述的一种整体多路阀阀体铸件铸造方法，其特征在于，S7中浇注温度范围为1390℃-1430℃，浇注时间范围为18s-25s，出炉温度范围为1510℃-1530℃。
  3. 根据权利要求2所述的一种整体多路阀阀体铸件铸造方法，其特征在于，浇注完成后，在冒口中搅拌，进而防止形成无法补足的小熔池，达到补缩效果。
  4. 根据权利要求2所述的一种整体多路阀阀体铸件铸造方法，其特征在于，采用在所有主孔芯头处放置收缩间隙为1.5mm的石棉 布，当铸件膨胀时，将有1.5mm的间隙来防止主孔的弯曲，再结合所述专用冷铁的作用，使得主孔的直线度在1.0mm之内。
  5. 根据权利要求1所述的一种整体多路阀阀体铸件铸造方法，其特征在于，S2中还包括使用水基涂料，并在所述水基涂料中加入石墨粉，制成波美度范围为35°Bé-42°Bé的涂料。
  6. 根据权利要求1所述的一种整体多路阀阀体铸件铸造方法，其特征在于，S2中制作主芯的加热温度范围为150℃-170℃，射砂压力不小于0.6MPa，射砂时间不少于6s，固化时间不少于120s。
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