CN100488664C - Investment precision casting process for producing automobile I-shaped front shaft - Google Patents
Investment precision casting process for producing automobile I-shaped front shaft Download PDFInfo
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- CN100488664C CN100488664C CNB2007100097187A CN200710009718A CN100488664C CN 100488664 C CN100488664 C CN 100488664C CN B2007100097187 A CNB2007100097187 A CN B2007100097187A CN 200710009718 A CN200710009718 A CN 200710009718A CN 100488664 C CN100488664 C CN 100488664C
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- Mold Materials And Core Materials (AREA)
Abstract
The invention relates to a precision investment casting process for producing an automobile I-shaped front shaft, which is prepared according to the following process steps in sequence: (1) manufacturing a wax mould; (2) coating paint on the surface of the wax mould, sanding and hardening the paint to form a mould shell, dewaxing and forming the mould shell; (3) roasting the formwork; (4) pouring the molten steel into a mould shell, analyzing and proportioning furnace materials before steelmaking, analyzing furnace materials before and after the steelmaking process, and adding necessary additives and deoxidizers so as to ensure that the smelted molten steel meets the requirements of specified chemical components; (5) removing a mould shell of the cast automobile I-shaped front shaft casting, and carrying out sand removal and casting head cutting; (6) polishing, trimming and inspecting the casting; (7) carrying out quenching and tempering heat treatment; (8) carrying out correction and shot blasting; (9) and performing metal cutting processing. The invention can not only greatly reduce the equipment investment and the die investment so as to reduce the production cost, but also has high speed and less investment for developing new varieties.
Description
Technical field
The present invention relates to the production and processing technology of automobile I-shaped front axle, particularly a kind of investment precision casting technology of producing automobile I-shaped front axle.
Background technology
Automobile I-shaped front axle (hereinafter to be referred as front axle) is the important safety part of automobile carrying.At present the front axle product of domestic each manufacturer all is to adopt Forging Technology, and the 45# forging is caused preceding axis blank, forms through heat treatment, metalworking, and its equipment investment, mould cost of investment are higher, and the speed of developing new product variety is slow, investment is bigger.
Summary of the invention
The object of the present invention is to provide a kind of investment precision casting technology of producing automobile I-shaped front axle, it not only can reduce equipment investment, mould investment greatly, thereby reduces production costs, and developing new product variety speed is fast, small investment.
Technical solution of the present invention is to constitute like this, it is characterized in that, it is according to following sequence of process steps preparation:
(1) makes wax-pattern according to the automobile I-shaped front axle blank shape: comprise casting, wax-pattern typing, wax-pattern repairing and check, wax-pattern assembly welding and the welding cap pouring port operation of carrying out successively;
(2) make formwork: 1. process the formwork preliminarily forming operation that the wax-pattern surface that makes is carried out several daub, stucco and made the coating sclerosis in step (1) earlier, 2. then dewax, formwork is separated with wax-pattern, form independent formwork;
(3) formwork of calcination steps (2) preparation;
(4) after making furnace lining, the chemical composition that will reach according to molten steel after the melting require and the burn out rate calculating melting of fusion process before the furnace charge chemical composition requirement that will reach, afterwards the charge composition that is used to make steel is carried out analyzing and testing and proportioning, thereby select for use the furnace charge of suitable proportioning and additive to carry out the molten steel melting; When furnace charge is smelted into liquid phase, chemical composition to molten steel is carried out on-the-spot sample analysis, if molten steel reaches the specified chemical composition requirement, then add pre-deoxidant ferromanganese 0.2-0.5% and ferrosilicon 0.05%-0.2%, proceed melting, if molten steel does not reach the specified chemical composition requirement, then adding makes its necessary additive that reaches the regulation chemical composition and above-mentioned pre-deoxidant; When smelting temperature reached 1570 ℃-1600 ℃, molten steel was come out of the stove into casting ladle, added earlier 0.05% aluminium in order to the molten steel final deoxidizing before going into casting ladle in casting ladle; At last pouring molten steel is gone in the good formwork of step (3) roasting; Above percentage is mass percent;
(5) the automobile I-shaped front axle foundry goods of step (4) moulding by casting is sloughed formwork, carry out sand removal and cut dead head;
(6) foundry goods that step (5) is processed is polished and is repaired and check;
(7) foundry goods that step (6) is processed carries out modified heat treatment;
(8) foundry goods that step (7) is processed is proofreaied and correct and bead;
(9) foundry goods that step (8) is processed carries out metal cutting processing processing.
Than prior art, the present invention is owing to creatively adopt investment precision casting technology to produce the automobile I-shaped front axle rough casting, again to rough casting heat-treat, metalworking to be to make product, therefore have the following advantages: (1) can reduce equipment investment, mould investment greatly, thereby reduces production costs; (2) fast, the small investment of developing new product variety speed, the time of adopting other method developing new product variety, about half a year to one year, mould took more than 200,000 yuan greatly, and utilize time＜3 that the present invention develops new product month, tool tool take＜0.5 ten thousand yuan; (3) product quality is good, have higher flexural strength and anti-fatigue life, the front axle product of the present invention's preparation is through national heavy-duty car quality supervision and test centers (Chongqing), Changchun Automobile Inst., China Automobile Industry Corp., country car mass supervision and inspection center (Xiangfan), the automotive research institute of automobile group of making a leapleap forward, national automotive researches such as Jinan automobile inspection center and the check unit test of many times, its fatigue life, it (is QC/T483-1999 that static bending intensity (rigidity) index all reaches the national sector standard requirement, QC/T494-1999), spontaneous production and marketing is sold this product over nearly 10 years, about 1,000,000 of sales volume, good through user's use certificate phaneroplasm amount, any problem does not appear.
Further improvement of the present invention also is: during steel-making, the material of making front axle adopts ZG40Cr low-alloy cast steel material to replace the used material (45# steel) of domestic in the past forging front axle, its furnace charge material that is used for melting automobile I-shaped front axle molten steel contains the chemical composition of following mass percent: carbon 0.4-0.45%, silicon 0.30%-0.40%, Mn0.60%-0.80%, chromium 0.80%-1.10%, P≤0.05%, S≤0.05%; The burn out rate that fusion process allows is silicon 0-5%, manganese 5-12%, carbon 5-12%, chromium 5-10%.Therefore improved the comprehensive mechanical performance of the front axle after the heat treatment greatly.
The specific embodiment
The following specific embodiment is elaborated to content of the present invention:
The present invention produces the investment precision casting technology of automobile I-shaped front axle, and it is according to following sequence of process steps preparation:
(1) makes wax-pattern according to the automobile I-shaped front axle blank shape: comprise casting, wax-pattern typing, wax-pattern repairing and check, wax-pattern assembly welding and the welding cap pouring port operation of carrying out successively;
(2) make formwork: 1. process the formwork preliminarily forming operation that the wax-pattern surface that makes is carried out several daub, stucco and made the coating sclerosis in step (1) earlier, 2. then dewax, formwork is separated with wax-pattern, form independent formwork;
(3) formwork of calcination steps (2) preparation;
(4) after making furnace lining, the chemical composition that will reach according to molten steel after the melting require and the burn out rate calculating melting of fusion process before the furnace charge chemical composition requirement that will reach, afterwards the charge composition that is used to make steel is carried out analyzing and testing and proportioning, thereby select for use the furnace charge of suitable proportioning and additive to carry out the molten steel melting; When furnace charge is smelted into liquid phase, chemical composition to molten steel is carried out on-the-spot sample analysis, if molten steel reaches the specified chemical composition requirement, then add pre-deoxidant ferromanganese 0.2-0.5% and ferrosilicon 0.05%-0.2%, proceed melting, if molten steel does not reach the specified chemical composition requirement, then adding makes its necessary additive that reaches the regulation chemical composition and above-mentioned pre-deoxidant; When smelting temperature reached 1570 ℃-1600 ℃, molten steel was come out of the stove into casting ladle, added earlier 0.05% aluminium in order to the molten steel final deoxidizing before going into casting ladle in casting ladle; At last pouring molten steel is gone in the good formwork of step (3) roasting; Above percentage is mass percent;
(5) the automobile I-shaped front axle foundry goods of step (4) moulding by casting is sloughed formwork, carry out sand removal and cut dead head;
(6) foundry goods that step (5) is processed is polished and is repaired and check;
(7) foundry goods that step (6) is processed carries out modified heat treatment;
(8) foundry goods that step (7) is processed is proofreaied and correct and bead;
(9) foundry goods that step (8) is processed carries out metal cutting processing processing.
The concrete preparation process and the technological requirement of above steps are described as follows:
(1) step and the technological requirement of making wax-pattern:
1. the preparation raw material of described wax-pattern is: paraffin 67%, stearic acid 33%; Adopting fusing point summer is 62-64 ℃ commercial wax, and adopting fusing point winter is 58 ℃ commercial wax; Described stearic acid adopts three to press one-levels or two to press the stearic acid of secondarys and fusing point 〉=58 ℃, oleic acid content≤10%; In the wax-pattern raw material, increase 5-10% stearic acid (to improve the softening point of mould material) summer, in the wax-pattern raw material, increase 5-20% paraffin (, preventing the wax-pattern cracking) winter to improve the intensity of mould material.
2. the following order of the preparation process of described wax-pattern is carried out:
(1) the dewaxing bucket adds water: fill up water to dewaxing barrel liner cover, energising heats water to 95 ℃;
(2) the dewaxing bucket is reinforced: the wax-pattern raw material that proportioning is good is put into the dewaxing bucket, and it is molten into liquefaction;
(3) stir the wax bucket and add water: fill up water to the water lining that stirs the wax bucket, energising heats water to 45-50 ℃;
(4) stirring the wax bucket feeds in raw material: add wax liquid and the equivalent wax bits sheet that has liquefied to stirring the wax bucket, addition is controlled at about half barrel;
(5) stir wax: energising is stirred, and adds wax liquid and wax bits sheet while stirring, and this process temperature is controlled at 46 ℃-48 ℃; Wait to stir after wax liquid is stirred into the pasty state that quality is even, denseness is suitable in the wax bucket, stop to stir, the wax material that stirs is standby;
(6) pressurized keg adds water: the water lining to wax injector fills up water, and 50-55 ℃ of summer, 55-60 ℃ of winter are heated water in energising;
(7) pressurized keg is reinforced: turn on the vent valve on the wax injector charging cylinder, guarantee that in-cylinder pressure is at 0 o'clock, open the charge door lid, pour the wax material that has stirred into to the material cylinder, fasten lid, close vent valve;
(8) pressurized keg pressurization: open the intake valve of charging cylinder, gauge pressure is controlled at 0.3-0.4Mpa;
(9) the wax-pattern aluminium pattern is annotated preceding cleaning: consider to be worth doing with the wax that clean gauze or hairbrush are removed on the die mould working face, and be coated with the last layer parting compound thinly;
(10) casting: will press the casting mouth of the wax outlet aligning aluminium pattern of wax rifle, the wax hydraulic pressure of wax injector material cylinder is gone in the aluminum dipping form die cavity, and when treating another wax outlet ejection wax liquid of aluminium pattern, lift casting rifle head, and stop pressure injection;
(11) pressurize: after pressure injection finishes, pressurize 20 seconds-1 minute, pressurize one finishes, and mentions and presses the wax rifle, covers casting mouth on the aluminium pattern with cast gate cushion block or cold wax stone immediately;
(12) cool off aluminium pattern: the aluminium pattern periphery of having annotated wax material is watered in a large number cool off, water and want evenly thoughtful, be no less than 2 minutes cool time;
(13) delivery and cooling: open aluminium pattern and take out wax-pattern, and put wax-pattern in cooling water continuation cooling, be no less than 15 minutes cool time, constantly stir wax-pattern in the cooling procedure;
(14) air cooling typing: take out wax-pattern and send into the typing chamber from cold water, be placed on the mould bases and finalize the design, the typing room temperature is controlled at 18-25 ℃;
(15) wax-pattern is repaired and is checked:
1. the wax-pattern that the typing chamber is taken out scrapes off unnecessary burr and overlap, to the position of depression and gaps and omissions,, fills with thick hot wax its boiling hotization of surface with hot pocket knife again, and wipe off the cooling back;
2. to the wax-pattern of distortion or distortion is arranged, it is put into proofread and correct after 30-35 ℃ hot water is macerated, put into cold water after the correction and finalize the design; To distortion or the excessive wax-pattern of deflection, do to scrap processing;
3. for repairing the curved surface that the rear surface difficulty is wipeed off, the pocket knife of using heat is with its boiling hotization of surface, strickling;
4. the wax-pattern that trims brushes away the wax bits with banister brush, neatly is emitted on the flat board, by the inspector it is checked one by one.
3. assembly welding process and technological requirement are as follows:
(1) be that 2-1.5mm weldering cutter heats on electric furnace with thickness;
Adopt which kind of gate stick when 1. every kind of wax-pattern welds bunchiness, the weldering several times, several grades of every weldering are all pressed the process chart regulation and are carried out;
2. the distance of two wax-patterns is 6-15mm, if corresponding be face-to-face, spacing should be got greatly, if in the face of line, puts or Line To Line, point-to-point then spacing can reduce;
3. going up most a wax-pattern must not be less than 70mm with the distance of burning the cup top;
4. the distance of next wax-pattern and cup bottom is 5-10mm;
5. wax-pattern and down gate should be at angle, get rid of gas when being convenient to dewax when mould material come-up and cast.
(2) two down gates should be welded in respectively on the soldering opening position of two spring plank faces.
(3) face of weld must weld comprehensively, stops to leave the space between dry joint and solder side.
(4) after wax-pattern weldering finishes, must the self check welding quality, remove that wax drips and the wax bits, be placed on clean ground or be held on the frame, stand-by.
(2) manufacturing process of formwork and technological requirement are as follows:
When (1) making formwork, the dope layer on wax-pattern surface is made up of one deck surface layer, three layers of transition zone and one deck enhancement Layer from the inside to the outside successively, and the raw material weight umber proportioning and the technological requirement of each dope layer are as follows:
1. surface layer: 1 part of waterglass, 9# silica flour 1.2-1.25 part, 0.15 part of degreasing agent, 0.05 part of defrother, with the viscosity 18-48 second that the viscosimeter water clock time is determined, firm time 20-30 minute, air-dry time was that 60～90 minutes summers, winter are more than 120 minutes; Wherein the density of waterglass is the 1.27-1.29 gram per centimeter
3
2. transition zone: 1 part of waterglass, 9# silica flour 1-1.1 part, with the viscosity 16-45 second that the viscosimeter water clock time is determined, firm time 30-40 minute, air-dry time was identical with surface layer; Wherein the density of waterglass is the 1.29-1.31 gram per centimeter
3
3. enhancement Layer: 1 part of waterglass, 0.6 part of 8# silica flour returns 0.4 part of the 8# silica flour of system, and with the viscosity 20-50 second that the viscosimeter water clock time is determined, firm time is 20-30 minute summer, 120 minutes winters, and air-dry time is identical with surface layer; Wherein the density of waterglass is the 1.34-1.36 gram per centimeter
3
The viscosity of above-mentioned surface layer, transition zone and enhancement Layer is got low value in the scope in summer, the high value of getting winter in the scope (can reduce waterglass proportion for the assurance appropriate viscosity in the winter time in right amount, and can not make the powder liquor ratio be lower than low value, particularly important to surface layer, under the situation of 9# quartz powder materials steady sources, can control the powder liquor ratio according to dope viscosity, but will consider the temperature Change factor); The SiO of 9# silica flour
2Content 〉=98%, fusing point 〉=1680 ℃, by 220 purpose content the above residual quantity of 70%, 200 orders≤10%; The SiO of 8# silica flour
2Content 〉=98%, fusing point 〉=1660 ℃, all by 220 orders;
Daub, stucco when (2) making formwork and the process that coating is hardened are according to following steps in sequence:
1. according to being coated with dope layer,, adjust waterglass, make it reach setting by the related process requirement of corresponding dope layer in this claim (1) money;
2. according to being coated with dope layer, the related process requirement by corresponding dope layer in this claim (1) money takes by weighing waterglass and silica flour and pours in the coating cylinder;
3. start mixer and stir, in coating till the no dry powder agglomerate;
4. preliminary survey dope viscosity is if the surface layer daub also need add degreasing agent and defrother by the requirement of this claim (1) money;
5. adjust dope viscosity to this claim (1) money medium viscosity prescribed limit, continue to stir more than 20 minutes;
6. after the coating that stirs will be placed 4 hours, make that waterglass and quartz powder materials are further wetting, bubble is floating just can use after overflowing;
7. wax-pattern dip-coating material, according to following steps with require to carry out successively:
A. control angle and speed that wax-pattern immerses coating, do not fracture when soaking and pressure-off wax-pattern, coating easily enter hole and is difficult for again causing that around the corner bubble is a principle with wax-pattern;
B. after wax-pattern immerses coating, move up and down lightly and come back rotation;
C. mention wax-pattern, avoid wax-pattern to come off from gate stick;
D. point out with little oil pike for the bubble on the wax-pattern, and add coating coating;
E. after mentioning wax-pattern, light drops down by coating and drips, and then rotate on the limit, and turn up and down on the limit, makes coating can be coated on the wax-pattern surface equably;
8. stucco may further comprise the steps and requires:
A. make wax-pattern constantly come back rotation and turned upside down during stucco, coating and sand grains are evenly distributed, anti-leak-stopping spreads;
B. stucco finishes and shakes off unnecessary sand grains;
C. stucco must be moved fast, and is in order to avoid the coating at water caltrop edge does not glue sand grains from doing, particularly important when summer or modulus of water glass are high;
D. wherein the stucco proportioning of enhancement Layer is: return the 3# quartz sand 80%+3# quartz sand 20% of system, wherein the order number of 3# quartz sand is 5/8;
9. coating sclerosis may further comprise the steps and requires:
The wax-pattern that a. will spread sand hangs to immerse and is placed with in the sclerosis pond of curing agent, make coating surface immediately with waterglass generation sclerous reaction, the silicon dioxide colloid of generation bonds together quartz sand and powder securely;
B. firm time is with reference to this claim (1) money (firm time is too short, can produce problems such as layering, bulging, intensity are not high during the formwork roasting, and firm time is long, then formwork meeting embrittlement, easy to crack);
C. float owing to the wax-pattern that will tie ground floor sand is placed on sclerosis Chi Zhonghui, often stir wax-pattern to guarantee each position homogeneous immersion;
10. air-dry, may further comprise the steps and require:
A. after mentioning wax-pattern, stop the several seconds, allow curing agent trickle back to harden behind the pond, be placed on the frame again or the ground;
B. the fan that begins to rehearse dries up moisture content;
C. air-dry time is with reference to this claim (1) money, the degree that makes the formwork surface reach " not wet in vain " (influences because of air-dry effect is subjected to air, temperature, humidity etc., therefore can be used as the foundation of air-dry time according to formwork surface " not wet in vain ", " in vain " be because of the formwork surface too drying separate out the sal-ammoniac crystal, resemble and draped over one's shoulders the white hair of one deck; " wet " and be meant to also have tangible drop on the formwork);
D. if " in vain " sent out on formwork surface, but need spray or soak wetting after next coating of dip-coating;
When e. having drop to retain as if the formwork bottom, the lengthening air-dry time;
When f. enhancement Layer coating has been tied, in the formwork groove, add a reinforcing bar, and twine the jail, to strengthen form strength with thin wire;
(3) dewaxing makes formwork separate with wax-pattern, and the process that forms independent formwork is in sequence according to the following steps:
1. add the clear water that accounts for tankage about 3/4 in the dewaxing pond, and add the sal-ammoniac that accounts for water weight 6～8%, with the water heating, water temperature is controlled in 90 ± 5 ℃ of scopes;
2. after removing the sand grains on the wax-pattern formwork, will be with the wax-pattern of formwork to be arranged in the hanging basket;
3. when water temperature reaches 90～95 ℃ (when the water surface has a small amount of bubble to seethe) puts into the pond with hanging basket;
4. after treating the wax-pattern mould material fusing in the cup, be welded on the wooden stick that is used to form cap pouring port on the wax-pattern before taking out, when treating to no longer include lasting white wax pearl come-up in the cup (generally being no more than 45 minutes), hanging basket is mentioned (not allowing to shorten the time of melting wax-pattern to boiling temperature) to improve water temperature;
When 5. formwork proposed the dewaxing pond, while rock water and the floating wax of pouring out wherein, jar was gone into the hot water injection again, formwork is placed upside down on the clean ground at last;
6. will take off the formwork of wax and place more than 8 hours, just carry out next step roasting.
(4) described degreasing agent is commercially available remover; Described defrother is n-octyl alcohol C
8H
180Described curing agent adopts weight percent concentration 〉=21.5%, pH value to form for industrial or agriculture the pairing with ammonium chloride solution and water of 5-6, the parts by weight proportioning value of wherein industrial ammonium chloride solution and water is 1:4, and agricultural is 1.1:4 with the parts by weight proportioning value of ammonium chloride solution and water.
(5) the wax material removal process is as follows:
1. (the wax material capacity about 70% in the cylinder) adding vapours is come heat temperature raising in wax material recovery cylinder;
2. treat wax material liquation boiling 60-90 minute, add 1～2% concentrated sulfuric acid or 3～5% technical hydrochloric acids of wax material amount;
3. continue boiling 3～5 minutes, no white saponified pearl point is till brown or the light yellow transparent liquid in wax liquid, stops heating;
4. left standstill 60～90 minutes, and took off limit winter, capping made impurity be sunken to the bottom, and began to occur wax liquid at the edge of cylinder and condense summer;
5. upper clear supernate has been ladled out gently with wooden dipper, watered into wax disk(-sc), required cylinder bottom should leave the wax liquid of 10-15 cm thick.
(3) the roasting formwork may further comprise the steps:
The roasting formwork may further comprise the steps:
(1) surface, position of the weak frangibility of the formwork after dewaxing is coated with cream earlier; The material mixture ratio that is coated with cream is: 50-60% enhancement Layer coating+70/40 order quartz sand, and wherein enhancement Layer coating contains: 0.4 part of the 8# silica flour of 1 part of waterglass, 8# silica flour 0.6 part, time system; Wherein the density of waterglass is the 1.34-1.36 gram per centimeter
3, the SiO of 8# silica flour
2Content 〉=98%, fusing point 〉=1660 ℃, all by 220 orders;
(2) then oneself is coated with the formwork that cream crosses and carries out low temperature drying, its technology controlling and process requires as follows: charging temperature＜50 ℃, and temperature rise control: 150-200 ℃, temperature retention time: 1.5-2 hour;
(3) will lift into stove through the good formwork of low temperature drying and carry out roasting, its technology controlling and process requires as follows: charging temperature＜400 ℃, and temperature rise control: 800-850 ℃, temperature retention time: 1-2 hour;
(4) roasting is good formwork is come out of the stove: after formwork is come out of the stove, should check the quality of formwork, its surface color should be white or white powder (formwork after the roasting when depositing, show occur long " white hair " phenomenon).
When (four) making steel, the furnace charge material that is used for melting automobile I-shaped front axle molten steel should contain the chemical composition of following mass percent: carbon 0.4-0.45%, silicon 0.30%-0.40%, Mn0.60%-0.80%, chromium 0.80%-1.10%, P≤0.05%, S≤0.05%; The burn out rate that fusion process allows is silicon 0-5%, manganese 5-12%, carbon 5-12%, chromium 5-10%.
I-shaped front axle molten steel smelting technology is described as follows:
1. smelting equipment technological requirement: select the capital equipment of intermediate frequency controllable silicon electric induction furnace for use as melting I-shaped front axle molten steel.
2. induction furnace inner chamber crucible furnace lining material technological requirement:
(1) quartz sand (powder) composition requires: SiO
2〉=98%, CaO＜0.5%, Feo+Fe
2O
3＜0.5%, clay＜0.4%;
(2) binding agent: an amount of boric acid.
3. crucible furnace lining manufacture craft:
(1) should check whether inductor seeps water, and its surface should wipe clean before the brickwork lining;
(2) spread the electrolysis asbestos cloth of a multiple bed thickness 1.5-2.5mm at the induction coil inner chamber, and make it to form cylinder;
(3) upper end with asbestos cloth is fixed on the furnace panel;
(4) sprinkle the furnace lining material that one deck is mixed at furnace bottom, thickness 40-50mm, and with the even tamping of plane bottom hammer;
(5) draw the pine surface and continue the spreading tamping, go round and begin again, till tamping face and induction coil bottom first lap;
(6) put the crucible original mold, the two central lines is put the furnace charge fixed position in the crucible original mold;
(7) draw tamping layer around the loose original mold, spread gainster, tamping successively is up to till the original mold upper end flushes;
(8) with 70% the gainster+30% fire clay tamping stove neck and the water nozzle of tapping;
(9) the tamped liner requirement is solid and even, and crackle must not be arranged.
4. sintered lining:
(1) the new good crucible furnace lining of tamping will pass through airing.
(2) fill it up with furnace charge in the crucible, the energising heating comes sintered lining with the melting molten steel.
(3) treat furnace charge all after the fusing, keep and go out molten steel about half an hour again.
(4) check that crucible has flawless, have and then mend it not have and then repeat above furnace burdening sintering is once again.
(5) the good crucible of sintering, its surface has the sinter layer of one deck 2-5 millimeters thick, and is closely knit and hard, smooth surface and shinny.
5.ZG40Cr front axle steel-making furnace charge chemical analysis requirement
6. each melting loss of elements rate of fusion process:
7. fusion process operating procedure:
(1) by the 5th, 6 section of analysis steel-making furnace charge composition and calculating batching and additive amount;
(2) charging:
Additives such as the 1. crucible bottom part cobbing of packing into, and corresponding ferrochrome, ferromanganese.
2. at the bulk material of loading onto infusibility near the sidewall of crucible place, meltable material piece is adorned at the center.
3. the bottom furnace charge will be adorned tightlier, and top is pine slightly.
(3) heating melting:
1. send before the electrical heating, induction furnace should lead to cooling water earlier, cooling water resistivity 〉=2500 ohmcms, pH value between 6-9, inflow temperature＜30 ° C, leaving water temperature＜50 ° C;
2. the energising that closes a switch, potentiometer handle on the adjustment doors makes negative bias voltage 7.5-10V;
3. press down the intermediate frequency play button, regulate power, in the time of at first 5-15 minute, give lower-wattage: 30-50KW;
4. after treating that electric current steadily, then carry out melting with peak power;
5. along with the fusing of furnace charge, the furnace charge of failing to have loaded should be added successively;
When 6. liquid metal occurring, add a small amount of slag former immediately;
7. fusion process will be turned over furnace charge gently with iron staff, makes it timely sinking, prevents that " bridging " phenomenon from taking place;
8. after treating that furnace charge all melts, skim, and get the on-the-spot sample analysis sample;
9. according to the chemico-analytic result in stokehold, adjust the feed supplement of composition and calculate;
10. according to calculating, weigh carburant, pre-deoxidant ferromanganese 0.2-0.5% and ferrosilicon 0.05%-0.2% and add in the smelting furnace successively;
8. pouring molten steel.
(1) casting ladle of accepting molten steel should be put the aluminium of putting about 0.05% in advance, in order to deoxidation.
When (2) going out molten steel, crucible is aimed at the double formula casting ladle of lifting, and molten steel should steadily inject casting ladle, and the overflow phenomena of splashing mustn't be arranged;
(3) take chemical analysis chemical examination sample behind the stove;
(4) when cast, accomplish that drainage standard, beam are steady, receive that stream is slow, cast continues to flow, the cup planted agent is full of molten steel all the time; Ladle spout and dead head distance should be controlled between 50 to 100mm.
(5) shelling of foundry goods processing and cutting dead head process and technological requirement are as follows:
(1) foundry goods shelling processing procedure is as follows: after molten steel pours into formwork, treat that temperature is reduced to about 500 ℃ after, use weight to knock the gate stick top and allow the formwork vibrations are broken and fall (do not knock on workpiece body when knocking, be strictly on guard against shake hinder, hammer into shape bad foundry goods);
(2) (regulate the pressure of oxygen and acetylene before the cutting earlier, cut surface requires big extremely smooth, must not hurt the foundry goods body, cuts surplus of back and answers＜6mm to utilize oxygen one acetylene flame to cut dead head.
(6) as follows to the polishing dressing process of foundry goods:
Earlier with the dead head trace, burr, overlap and the local crowning that cut away on the formed grinding wheel polishing foundry goods; Then the foul of the spilehole on the foundry goods, cinder hole, sand holes burning into sand and so on blemish surface is removed, with arc welding defective is carried out soldering (electric arc generally is controlled at 2-3mm during soldering) afterwards, with emery wheel the mending of iron castings place is polished at last with chisel, emery wheel.
(7) heat treated process and technological requirement are as shown in the table:
(8) metalworking processing procedure comprises following sequential steps:
1. rough mill the leaf spring face;
2. finish-milling leaf spring face;
3. rough mill the stub face;
4. brill kingpin bore;
5. boring kingpin bore;
6. (1) bores shock relieve vent-ream shock relieve vent both ends of the surface-hinge shock relieve vent;
(2) bore leaf spring hole-spot-facing plane (counterbore);
(3) finish-milling (mill) stub face-brill lateral pin hole-brill (counterbore);
(4) bore earhole tapping-spot-facing plane;
7. hinge kingpin bore.
Add man-hour, should make flatness≤0.35 of two leaf spring faces, two ends is to drop size≤0.5 of leaf spring face, linearity≤0.35 of two ends head and whole shaft centre line.
(9) after metalworking is handled, also to carry out grinding process to product, check (flaw detection), the paintbrush word pastes the quality certification, last warehouse entry.
The I-shaped front axle product that the our factory produces, material is a ZG40Cr low-alloy steel, adopt the I-shaped front axle of 45# steel production to compare with at present domestic each producer, after modified heat treatment, improved comprehensive mechanical performance, have higher flexural strength and anti-fatigue life, in the production of product,, make the chemical analysis of product stable owing to adopted the technical matters and the strict quality control system of some original creation, and solved problems such as pore, folder quarrel, crackle effectively, guaranteed product quality.
This product aborning, the major quality controlling point:
1, chemical examination: during the hot investment casting blank, every stove product stokehold stove post analysis twice, main project: C, Si, Mn, Cr, Mo, S, P guarantee to reach 40Cr, the requirement of 42CrMo steel national standard.
2, heat treatment: after every batch of product heat treatment, carry out Metallographic Analysis, hardness detection.
3, mechanical test: the every batch of product is done tensile strength and percentage elongation test.
4, pressure testing: every product blank, carry out pressure testing with 160 tons of hydraulic presses, and proofread and correct.Improved product quality reliability.
5, defect detecting test: every product carries out defect detecting test with magna-check (fluorescent magnetic), has stopped faulty goods warehouse entries such as crackle.
Claims (10)
1. an investment precision casting technology of producing automobile I-shaped front axle is characterized in that, it is according to following sequence of process steps preparation:
(1) makes wax-pattern according to the automobile I-shaped front axle blank shape: comprise casting, wax-pattern typing, wax-pattern repairing and check, wax-pattern assembly welding and the welding cap pouring port operation of carrying out successively;
(2) make formwork: 1. process the formwork preliminarily forming operation that the wax-pattern surface that makes is carried out several daub, stucco and made the coating sclerosis in step (1) earlier, 2. then dewax, formwork is separated with wax-pattern, form independent formwork;
(3) formwork of calcination steps (2) preparation;
(4) after making furnace lining, the chemical composition that will reach according to molten steel after the melting require and the burn out rate calculating melting of fusion process before the furnace charge chemical composition requirement that will reach, afterwards the charge composition that is used to make steel is carried out analyzing and testing and proportioning, thereby select for use the furnace charge of suitable proportioning and additive to carry out the molten steel melting; When furnace charge is smelted into liquid phase, chemical composition to molten steel is carried out on-the-spot sample analysis, if molten steel reaches the specified chemical composition requirement, then add pre-deoxidant ferromanganese 0.2-0.5% and ferrosilicon 0.05%-0.2%, proceed melting, if molten steel does not reach the specified chemical composition requirement, then adding makes its necessary additive that reaches the regulation chemical composition and above-mentioned pre-deoxidant; When smelting temperature reached 1570 ℃-1600 ℃, molten steel was come out of the stove into casting ladle, added earlier 0.05% aluminium in order to the molten steel final deoxidizing before going into casting ladle in casting ladle; At last pouring molten steel is gone in the good formwork of step (3) roasting; Above percentage is mass percent;
(5) the automobile I-shaped front axle foundry goods of step (4) moulding by casting is sloughed formwork, carry out sand removal and cut dead head;
(6) foundry goods that step (5) is processed is polished and is repaired and check;
(7) foundry goods that step (6) is processed carries out modified heat treatment;
(8) foundry goods that step (7) is processed is proofreaied and correct and bead;
(9) foundry goods that step (8) is processed carries out metal cutting processing processing.
2. the investment precision casting technology of production automobile I-shaped front axle according to claim 1 is characterized in that: the preparation raw material of described wax-pattern is: paraffin 67%, stearic acid 33%; The following order of the preparation process of described wax-pattern is carried out:
(1) the dewaxing bucket adds water: fill up water to dewaxing barrel liner cover, energising heats water to 95 ℃;
(2) the dewaxing bucket is reinforced: the wax-pattern raw material that proportioning is good is put into the dewaxing bucket, and it is molten into liquefaction;
(3) stir the wax bucket and add water: fill up water to the water lining that stirs the wax bucket, energising heats water to 45-50 ℃;
(4) stirring the wax bucket feeds in raw material: add wax liquid and the equivalent wax bits sheet that has liquefied to stirring the wax bucket, addition is controlled at about half barrel;
(5) stir wax: energising is stirred, and adds wax liquid and wax bits sheet while stirring, and this process temperature is controlled at 46 ℃-48 ℃; Wait to stir after wax liquid is stirred into the pasty state that quality is even, denseness is suitable in the wax bucket, stop to stir, the wax material that stirs is standby;
(6) pressurized keg adds water: the water lining to wax injector fills up water, and 50-55 ℃ of summer, 55-60 ℃ of winter are heated water in energising;
(7) pressurized keg is reinforced: turn on the vent valve on the wax injector charging cylinder, guarantee that in-cylinder pressure is at 0 o'clock, open the charge door lid, pour the wax material that has stirred into to the material cylinder, fasten lid, close vent valve;
(8) pressurized keg pressurization: open the intake valve of charging cylinder, gauge pressure is controlled at 0.3-0.4Mpa;
(9) the wax-pattern aluminium pattern is annotated preceding cleaning: consider to be worth doing with the wax that clean gauze or hairbrush are removed on the die mould working face, and be coated with the last layer parting compound thinly;
(10) casting: will press the casting mouth of the wax outlet aligning aluminium pattern of wax rifle, the wax hydraulic pressure of wax injector material cylinder is gone in the aluminum dipping form die cavity, and when treating another wax outlet ejection wax liquid of aluminium pattern, lift casting rifle head, and stop pressure injection;
(11) pressurize: after pressure injection finishes, pressurize 20 seconds-1 minute, pressurize one finishes, and mentions and presses the wax rifle, covers casting mouth on the aluminium pattern with cast gate cushion block or cold wax stone immediately;
(12) cool off aluminium pattern: the aluminium pattern periphery of having annotated wax material is watered in a large number cool off, water and want evenly thoughtful, be no less than 2 minutes cool time;
(13) delivery and cooling: open aluminium pattern and take out wax-pattern, and put wax-pattern in cooling water continuation cooling, be no less than 15 minutes cool time, constantly stir wax-pattern in the cooling procedure;
(14) air cooling typing: take out wax-pattern and send into the typing chamber from cold water, be placed on the mould bases and finalize the design, the typing room temperature is controlled at 18-25 ℃;
(15) wax-pattern is repaired and is checked:
1. the wax-pattern that the typing chamber is taken out scrapes off unnecessary burr and overlap, to the position of depression and gaps and omissions,, fills with thick hot wax its boiling hotization of surface with hot pocket knife again, and wipe off the cooling back;
2. to the wax-pattern of distortion or distortion is arranged, it is put into proofread and correct after 30-35 ℃ hot water is macerated, put into cold water after the correction and finalize the design; To distortion or the excessive wax-pattern of deflection, do to scrap processing;
3. for repairing the curved surface that the rear surface difficulty is wipeed off, the pocket knife of using heat is with its boiling hotization of surface, strickling;
4. the wax-pattern that trims brushes away the wax bits, is emitted on the flat board, by the inspector it is checked one by one.
3. the investment precision casting technology of production automobile I-shaped front axle according to claim 2 is characterized in that: adopting fusing point summer is 62-64 ℃ commercial wax, and adopting fusing point winter is 58 ℃ commercial wax; Described stearic acid adopts three to press one-levels or two to press the stearic acid of secondarys and fusing point 〉=58 ℃, oleic acid content≤10%; In the wax-pattern raw material, increase the 5-10% stearic acid summer, in the wax-pattern raw material, increase 5-20% paraffin winter.
4. according to the investment precision casting technology of claim 1 or 2 or 3 described production automobile I-shaped front axles, it is characterized in that:
When (1) making formwork, the dope layer on wax-pattern surface is made up of one deck surface layer, three layers of transition zone and one deck enhancement Layer from the inside to the outside successively, and the raw material weight umber proportioning and the technological requirement of each dope layer are as follows:
1. surface layer: 1 part of waterglass, 9# silica flour 1.2-1.25 part, 0.15 part of degreasing agent, 0.05 part of defrother, with the viscosity 18-48 second that the viscosimeter water clock time is determined, firm time 20-30 minute, air-dry time was that 60～90 minutes summers, winter are more than 120 minutes; Wherein the density of waterglass is the 1.27-1.29 gram per centimeter
3
2. transition zone: 1 part of waterglass, 9# silica flour 1-1.1 part, with the viscosity 16-45 second that the viscosimeter water clock time is determined, firm time 30-40 minute, air-dry time was identical with surface layer; Wherein the density of waterglass is the 1.29-1.31 gram per centimeter
3
3. enhancement Layer: 1 part of waterglass, 0.6 part of 8# silica flour returns 0.4 part of the 8# silica flour of system, and with the viscosity 20-50 second that the viscosimeter water clock time is determined, firm time is 20-30 minute summer, 120 minutes winters, and air-dry time is identical with surface layer; Wherein the density of waterglass is the 1.34-1.36 gram per centimeter
3
The viscosity of above-mentioned surface layer, transition zone and enhancement Layer is got low value in the scope in summer, gets the high value in the scope winter; The SiO of 9# silica flour
2Content 〉=98%, fusing point 〉=1680 ℃, by 220 purpose content the above residual quantity of 70%, 200 orders≤10%; The SiO of 8# silica flour
2Content 〉=98%, fusing point 〉=1660 ℃, all by 220 orders;
Daub, stucco when (2) making formwork and the process that coating is hardened are according to following steps in sequence:
1. according to being coated with dope layer,, adjust waterglass, make it reach setting by the related process requirement of corresponding dope layer in this claim (1) money;
2. according to being coated with dope layer, the related process requirement by corresponding dope layer in this claim (1) money takes by weighing waterglass and silica flour and pours in the coating cylinder;
3. start mixer and stir, in coating till the no dry powder agglomerate;
4. preliminary survey dope viscosity is if the surface layer daub also need add degreasing agent and defrother by the requirement of this claim (1) money;
5. adjust dope viscosity to this claim (1) money medium viscosity prescribed limit, continue to stir more than 20 minutes;
6. after the coating that stirs will be placed 4 hours, make that waterglass and quartz powder materials are further wetting, bubble is floating just can use after overflowing;
7. wax-pattern dip-coating material, according to following steps with require to carry out successively:
A. control angle and speed that wax-pattern immerses coating, do not fracture when soaking and pressure-off wax-pattern, coating easily enter hole and is difficult for again causing that around the corner bubble is a principle with wax-pattern;
B. after wax-pattern immerses coating, move up and down lightly and come back rotation;
C. mention wax-pattern, avoid wax-pattern to come off from gate stick;
D. point out with little oil pike for the bubble on the wax-pattern, and add coating coating;
E. after mentioning wax-pattern, light drops down by coating and drips, and then rotate on the limit, and turn up and down on the limit, makes coating can be coated on the wax-pattern surface equably;
8. stucco may further comprise the steps and requires:
A. make wax-pattern constantly come back rotation and turned upside down during stucco, coating and sand grains are evenly distributed, anti-leak-stopping spreads;
B. stucco finishes and shakes off unnecessary sand grains;
C. stucco must be moved fast, and is in order to avoid the coating at water caltrop edge does not glue sand grains from doing, particularly important when summer or modulus of water glass are high;
D. wherein the stucco proportioning of enhancement Layer is: return the 3# quartz sand 80%+3# quartz sand 20% of system, wherein the order number of 3# quartz sand is 5/8;
9. coating sclerosis may further comprise the steps and requires:
The wax-pattern that a. will spread sand hangs to immerse and is placed with in the sclerosis pond of curing agent, make coating surface immediately with waterglass generation sclerous reaction, the silicon dioxide colloid of generation bonds together quartz sand and powder securely;
B. firm time is with reference to this claim (1) money;
C. often stir wax-pattern to guarantee each position homogeneous immersion;
10. air-dry, may further comprise the steps and require:
A. after mentioning wax-pattern, stop the several seconds, allow curing agent trickle back to harden behind the pond, be placed on the frame again or the ground;
B. the fan that begins to rehearse dries up moisture content;
C. air-dry time makes the formwork surface reach the degree of " not wet in vain " with reference to this claim (1) money;
D. if " in vain " sent out on formwork surface, but need spray or soak wetting after next coating of dip-coating;
When e. having drop to retain as if the formwork bottom, the lengthening air-dry time;
When f. enhancement Layer coating has been tied, in the formwork groove, add a reinforcing bar, and twine the jail, to strengthen form strength with thin wire;
(3) dewaxing makes formwork separate with wax-pattern, and the process that forms independent formwork is in sequence according to the following steps:
1. add the clear water that accounts for tankage about 3/4 in the dewaxing pond, and add the sal-ammoniac that accounts for water weight 6～8%, with the water heating, water temperature is controlled in 90 ± 5 ℃ of scopes;
2. after removing the sand grains on the wax-pattern formwork, will be with the wax-pattern of formwork to be arranged in the hanging basket;
3. when water temperature reaches 90～95 ℃, hanging basket is put into the pond;
4. after treating the wax-pattern mould material fusing in the cup, be welded on the wooden stick that is used to form cap pouring port on the wax-pattern before taking out, when treating to no longer include lasting white wax pearl come-up in the cup, hanging basket mentioned;
When 5. formwork proposed the dewaxing pond, while rock water and the floating wax of pouring out wherein, jar was gone into the hot water injection again, formwork is placed upside down on the clean ground at last;
6. will take off the formwork of wax and place more than 8 hours, just carry out next step roasting.
5. the investment precision casting technology of production automobile I-shaped front axle according to claim 4 is characterized in that: described degreasing agent is commercially available remover; Described defrother is n-octyl alcohol C
8H
18O; Described curing agent adopts weight percent concentration 〉=21.5%, pH value to form for industrial or agriculture the pairing with ammonium chloride solution and water of 5-6, the parts by weight proportioning value of wherein industrial ammonium chloride solution and water is 1:4, and agricultural is 1.1:4 with the parts by weight proportioning value of ammonium chloride solution and water.
6. according to the investment precision casting technology of claim 1 or 2 or 3 described production automobile I-shaped front axles, it is characterized in that: the roasting formwork may further comprise the steps:
(1) surface, position of the weak frangibility of the formwork after dewaxing is coated with cream earlier; The material mixture ratio that is coated with cream is: 50-60% enhancement Layer coating+70/40 order quartz sand, and wherein enhancement Layer coating contains: 0.4 part of the 8# silica flour of 1 part of waterglass, 8# silica flour 0.6 part, time system; Wherein the density of waterglass is the 1.34-1.36 gram per centimeter
3, the SiO of 8# silica flour
2Content 〉=98%, fusing point 〉=1660 ℃, all by 220 orders;
(2) then oneself is coated with the formwork that cream crosses and carries out low temperature drying, its technology controlling and process requires as follows: charging temperature＜50 ℃, and temperature rise control: 150-200 ℃, temperature retention time: 1.5-2 hour;
(3) will lift into stove through the good formwork of low temperature drying and carry out roasting, its technology controlling and process requires as follows: charging temperature＜400 ℃, and temperature rise control: 800-850 ℃, temperature retention time: 1-2 hour;
(4) roasting is good formwork is come out of the stove: after formwork is come out of the stove, should check the quality of formwork, its surface color should be white or white powder.
7. according to the investment precision casting technology of claim 1 or 2 or 3 described production automobile I-shaped front axles, it is characterized in that: during steel-making, the furnace charge material that is used for melting automobile I-shaped front axle molten steel should contain the chemical composition of following mass percent: carbon 0.4-0.45%, silicon 0.30%-0.40%, Mn0.60%-0.80%, chromium 0.80%-1.10%, phosphorus≤0.05%, sulphur≤0.05%; The burn out rate that fusion process allows is silicon 0-5%, manganese 5-12%, carbon 5-12%, chromium 5-10%.
8. according to the investment precision casting technology of claim 1 or 2 or 3 described production automobile I-shaped front axles, it is characterized in that: foundry goods shelling processing procedure is as follows: after molten steel pours into formwork, after treating that temperature is reduced to about 500 ℃, use weight to knock the gate stick top and allow the formwork vibrations are broken to fall; Cut dead head afterwards.
9. according to the investment precision casting technology of claim 1 or 2 or 3 described production automobile I-shaped front axles, it is characterized in that: when foundry goods is carried out modified heat treatment, 860 ± 10 ℃ of quenching temperatures, temperature retention time 150 ± 10min; Adopt water as cooling medium, 70-75 second cool time; Temperature 560-565 ℃, temperature retention time 170 minutes.
10. according to the investment precision casting technology of claim 1 or 2 or 3 described production automobile I-shaped front axles, it is characterized in that: the polishing dressing process to foundry goods is as follows: earlier with the dead head trace, burr, overlap and the local crowning that cut away on the formed grinding wheel polishing foundry goods; Then the foul of the spilehole on the foundry goods, cinder hole, sand holes burning into sand and so on blemish surface is removed, with arc welding defective is carried out soldering afterwards, with emery wheel the mending of iron castings place is polished at last with chisel, emery wheel.
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| Application Number | Priority Date | Filing Date | Title |
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| CNB2007100097187A CN100488664C (en) | 2007-10-29 | 2007-10-29 | Investment precision casting process for producing automobile I-shaped front shaft |
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|---|---|---|---|
| CNB2007100097187A CN100488664C (en) | 2007-10-29 | 2007-10-29 | Investment precision casting process for producing automobile I-shaped front shaft |
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| CN100488664C true CN100488664C (en) | 2009-05-20 |
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