Size design method of ring structure casting

Abstract

The invention relates to a size design method of a ring structure casting, which comprises height size reversible deformation design and radius size reversible deformation design, the height size reversible deformation design is to mark a plurality of first measurement points on the top surface and / or the bottom surface of the casting, and the first measurement points of each measurement surface are measured and analyzed, so that the size of the casting is determined. Obtaining a height dimension reversible deformation pasting amount formula; according to the radius size reversible deformation design, a plurality of second measuring points are marked on the inner surface and / or the outer surface of the casting, and the second measuring points of all angles are measured and analyzed to obtain a radius size reversible deformation sticking amount formula; and calculating a corresponding size pasting amount through a reversible deformation pasting amount formula, and carrying out reversible deformation design. According to the size design method of the ring structure casting, asymmetric design is carried out on the process sticking quantity of the two sides of the T-shaped structure, non-uniform design is carried out on the process sticking quantity of the inner diameter and the outer diameter, asymmetric and non-uniform shrinkage deformation of the casting is counteracted, and then the machining allowance is uniform after the casting is solidified and deformed.

Description

Technical Field

[0001] The invention relates to the technical field of casting, in particular to a size design method for a ring-type structure casting. Background Art

[0002] The gear of large-scale mining machinery mill is a ring-type structural casting. It belongs to the transmission device of large-scale mining machinery mill. The gear diameter is relatively large. The product needs to be cast in half during casting design. After machining, the two halves are assembled to form a large gear, which is used for power transmission of large-scale mining machinery mill. Its structural strength and dimensional accuracy have a great influence on its operating stability. The half-cast gear ring is a C-shaped structure when viewed from above, and a side T-shaped structure when viewed from the cross section. The overall structural strength of the half-casting is poor, and it is very easy to produce opening and twisting deformation. In addition, due to the design of the casting process, a riser is designed on one side above the side T-shaped structure, resulting in asymmetry on both sides of the T-shaped structure of the casting cross section. Asymmetric structural shrinkage deformation and opening deformation are very likely to occur during solidification shrinkage.

[0003] The uniform amount of pasting design method in the prior art is adopted to uniformly design the amount of pasting on the blank surface as a whole, and to uniformly design the machining allowance on the outer tooth surface and the upper and lower end machining surfaces of the casting. It was found that the casting was unevenly deformed due to the existence of the top surface riser. The shrinkage-compensating riser was designed on the upper end surface of the gear ring, which caused the overall structural height of the horizontal extension part on the inner side of the gear ring to shrink and deform beyond the riser side. The blank surface seriously exceeded the tolerance requirements of the customer's drawing. There was no machining allowance on the non-riser side of the height direction machining surface, and the machining allowance on the riser side was too large. After the gear ring was modeled and cast, the dimensional measurement before the quality heat treatment found that the gear ring shrank and deformed to one side in the height direction. There was no machining allowance on one side in the height direction, and the machining allowance on the other side was too large.

[0004] Half-casting is prone to mouth opening deformation. The inner diameter of the gear ring and the outer tooth surface are evenly attached. After the casting is poured and boxed, it goes through the riser cutting and quality heat treatment process. After the joint surface is cut in half, the size measurement is found to be serious. The inner diameter of the gear ring is lacking meat in the 0° area, the 90° area is too meaty, and the 180° area is lacking meat; the outer diameter tooth surface is too meaty in the 0° area, the 90° area is lacking meat, and the 180° area is too meaty. The rough surface seriously exceeds the dimensional tolerance requirements, requiring large-scale air gouging and welding repair. The large area of ​​the machined surface has a large machining allowance, and some areas do not have sufficient machining allowance. Summary of the invention

[0005] Based on this, it is necessary to provide a dimension design method for anti-deformation ring-type structural castings to address the above technical problems.

[0006] In order to solve the above problems, the present invention adopts the following technical solutions:

[0007] The embodiment of the present invention discloses a dimension design method for a ring-type structure casting, including height dimension anti-deformation design and radius dimension anti-deformation design; wherein, in the height dimension anti-deformation design, a plurality of first measurement points are marked on the top surface and / or bottom surface of the casting; the total height of the casting is evenly divided to find the center line; the deformation deviation value of each first measurement point is obtained based on the center line and the deformation deviation mean of the first measurement point of the same measurement surface is calculated; the deformation deviation mean of the first measurement point of each measurement surface is fitted to obtain a height dimension anti-deformation paste formula; the height dimension anti-deformation paste formula is used to calculate the paste of each height value of the casting, and the height dimension anti-deformation design of the casting is performed; in the radius dimension anti-deformation design, a plurality of second measurement points are marked on the inner surface and / or outer surface of the casting, and the deformation value of each second measurement point is obtained; the deformation mean of the second measurement point at the same angle is calculated; the deformation mean of the second measurement point at each angle is fitted to obtain a radius dimension anti-deformation paste formula; the radius anti-deformation paste formula is used to calculate the paste of each radius value of the casting, and the radius dimension anti-deformation design of the casting is performed.

[0008] In one embodiment, the calculation formula of the mean value of the deformation of the first measuring point is:

[0009] x=(z1+z2+……+z n ) / n;

[0010] x is the mean value of the deformation deviation of the first measuring point on the same measuring surface, z is the deformation deviation value of the first measuring point on the same measuring surface, and n is the number of the first measuring points on the same measuring surface.

[0011] In one embodiment, the calculation formula of the deformation value of the first measuring point is:

[0012] z n =a n -(b+c);

[0013] z n is the deformation deviation value of the first measuring point, a n is the deviation between the measured value and the theoretical value of the first measuring point, b is the height design value of the plane corresponding to the first measuring point, and c is the height model deviation value of the plane corresponding to the first measuring point.

[0014] In one embodiment, the first measuring points are evenly spaced apart on the top surface and / or the bottom surface of the casting.

[0015] In one embodiment, the height dimension inverse deformation amount formula is:

[0016] y 顶面 =(3.95-0.0079×T×∠ 顶面 )~3.95;

[0017] y 底面 =3.95~(3.95+0.0079×T×∠ 底面 );

[0018] y 顶面 is the design value of the height dimension of the top surface of the casting, 底面 is the design value of the height dimension anti-deformation of the bottom surface of the casting, T is the theoretical width between the minimum radius and the maximum radius in the height direction of the casting, ∠ 顶面 is the deformation angle of the top surface of the casting in the height direction, ∠ 底面 is the deformation angle of the bottom surface of the casting in the height direction, 3.95 is the mean value of the measured deviation of the casting height, and 0.0079 is the height deformation coefficient;

[0019] ∠ 顶面 It is the ratio of the deviation between the measured value at the minimum radius and the measured value at the maximum radius in the height direction of the top surface of the casting to T;

[0020] ∠ 底面 It is the ratio of the measured value at the minimum radius in the height direction of the bottom surface of the casting to the measured value at the maximum radius and T.

[0021] In one embodiment, the calculation formula of the mean value of the deformation of the second measuring point is:

[0022] u=(d1+d2+……+d m ) / m;

[0023] u is the mean deformation of the second measurement point at the same angle, d m is the deformation value of the second measuring point at the same angle, and m is the number of the second measuring points at the same angle.

[0024] In one embodiment, the calculation formula of the deformation value of the second measuring point is:

[0025] d m =a m '-(b'+c');

[0026] d m is the deformation value of the second measuring point, a m ' is the radius value of the second measuring point, b' is the radius design value of the corresponding angle of the second measuring point, and c' is the radius model deviation value of the corresponding angle of the second measuring point.

[0027] In one embodiment, the radius dimension inverse deformation amount formula is:

[0028] Y=-(6.27+0.004×R-0.41×∠);

[0029] Y is the anti-deformation value of the casting radius size, 6.27 is the constant coefficient, 0.004 is the radius deformation coefficient, R is the theoretical radius of the casting, 0.41 is the angle deformation coefficient, and ∠ is an arbitrary angle.

[0030] In one embodiment, the second measuring points are evenly spaced apart on the inner surface or the outer surface of the casting.

[0031] The technical solution adopted by the present invention can achieve the following beneficial effects:

[0032] The dimension design method of the ring-type structure casting disclosed in the present invention performs asymmetrical design on the process allowances on both sides of the T-shaped structure to offset the shrinkage deformation of the asymmetrical structure, thereby making the processing allowance uniform after solidification deformation and the blank surface size qualified, thereby improving the machining efficiency and ensuring the uniform weight of both sides of the T-shaped structure of the gear ring. During the final assembly and use, the stability of the long-term rotation operation of the gear is ensured, and the service life is extended; through the reverse deformation dimension design, the processing allowance in the circumferential direction of the outer tooth surface and the inner diameter after deformation is reduced, the rough machining time of the outer tooth surface is reduced, and the rough machining cycle and rough machining cost of the casting are saved; the inner diameter blank size meets the customer's tolerance requirements after deformation, so that the overall weight in the circumferential direction is uniform, and the gear operation stability and performance are improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a top view of a mining machine gear casting;

[0034] Figure 2 This is the front view of the mining machine gear casting;

[0035] Figure 3 This is a schematic diagram of the height dimension anti-deformation design of the mining machine gear casting;

[0036] Figure 4 This is a schematic diagram of the anti-deformation design of the radius size of the mining machine gear casting;

[0037] 110-first measuring point; 120-second measuring point; 210-anti-deformation design of outer diameter; 220-anti-deformation design of inner diameter; 310-anti-deformation design of riser side; 320-anti-deformation design of non-riser side. DETAILED DESCRIPTION

[0038] In order to facilitate the understanding of the present invention, the present invention will be described more fully below with reference to the relevant drawings. The preferred embodiments of the present invention are given in the drawings. However, the present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the disclosure of the present invention more thoroughly understood.

[0039] It should be noted that when an element is referred to as being "disposed on" another element, it may be directly on the other element or there may be a centered element. When an element is considered to be "connected to" another element, it may be directly connected to the other element or there may be a centered element at the same time. The terms "vertical", "horizontal", "left", "right", "top", "bottom", "bottom end", "top end" and similar expressions used herein are for illustrative purposes only and are not intended to be the only implementation method.

[0040] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those commonly understood by those skilled in the art of the present invention. The terms used herein in the specification of the present invention are only for the purpose of describing specific embodiments and are not intended to limit the present invention. The term "and / or" used herein includes any and all combinations of one or more related listed items.

[0041] The embodiment of the present invention discloses a dimension design method for a ring-type structure casting. In order to more easily understand the concept of the present invention, this embodiment takes a mining machine gear casting as an example to specifically explain the dimension design method for a ring-type structure casting. The cross section of the mining machine gear casting is a side T-shaped structure. A full circle of risers are designed on one side of the side T-shaped structure, i.e., the top surface, and no risers are designed on the other side, i.e., the bottom surface. The riser side and the non-riser side form an asymmetric structure, which will cause asymmetric shrinkage deformation; the mining machine gear casting is cast in half, and the C-shaped structure will cause opening deformation. Ultimately, the machining allowance in some areas is too large, and the machining allowance in some areas is insufficient. In order to offset the above deformation, the dimension design method for a ring-type structure casting disclosed in the embodiment of the present invention may include a height dimension anti-deformation design and a radius dimension anti-deformation design, wherein the height dimension anti-deformation design is used to offset the asymmetric deformation of the riser side and the non-riser side of the mining machine gear casting, and the radius dimension anti-deformation design is used to offset the opening deformation of the mining machine gear casting.

[0042] The height dimension anti-deformation design method may include the following steps:

[0043] S110, such as Figure 1 As shown, a plurality of first measuring points 110 are marked on the top surface of the mining machine gear casting, i.e., the riser side. The first measuring points 110 can be evenly spaced and distributed in equal angle increments and equal radius increments in the circumferential direction of the mining machine gear casting. A plurality of first measuring points 110 can also be marked in a uniformly spaced and distributed manner on the bottom surface of the mining machine gear casting, i.e., the non-riser side.

[0044] S120. Divide the total height of the mining machine gear casting equally and find the center line.

[0045] S130, measuring the height of each first measuring point 110 based on the center line, and calculating the deformation value of each first measuring point 110. The calculation formula of the deformation value of the first measuring point 110 is:

[0046] z1=a1-(b+c), z2=a2-(b+c)……z n =a n -(b+c)……;

[0047] Among them, z is the deformation deviation value of the first measuring point 110, a is the deviation between the measured value and the theoretical value of the first measuring point 110, b is the height design value of the plane corresponding to the first measuring point 110, and c is the height model deviation value of the plane corresponding to the first measuring point 110.

[0048] S140, grouping the first measurement points 110 according to different measurement planes, and calculating the average deformation value of each group of first measurement points 110. The calculation formula for the average deformation value of the first measurement points 110 on the same measurement plane is:

[0049] x=(z1+z2+……+z n ) / n;

[0050] x is the average value of the deformation deviation of the first measuring points 110 on the same measuring surface, z is the deformation deviation value of the first measuring points 110 on the same measuring surface, and n is the number of the first measuring points 110 on the same measuring surface.

[0051] S150, fitting the deformation deviation mean of the first measuring point 110 of each measuring surface, obtaining the deviation between the measured value and the design value in the height direction of the mining machine gear casting, and calculating the deformation angle of the height plane by the ratio of the deviation to the theoretical width between the minimum radius and the maximum radius in the height direction of the mining machine gear casting. When the deformation angle in the height direction is known, the calculated deformation deviation is reversely designed during process design.

[0052] The formula for the inverse deformation of the height dimension is:

[0053] y 顶面 =(3.95-0.0079×T×∠ 顶面 )~3.95;

[0054] y 底面 =3.95~(3.95+0.0079×T×∠ 底面 );

[0055] y 顶面 is the design value of the height dimension of the top surface of the casting, 底面 is the design value of the height dimension anti-deformation of the bottom surface of the casting, T is the theoretical width between the minimum radius and the maximum radius in the height direction of the casting, ∠顶面 is the deformation angle of the top surface of the casting in the height direction, ∠ 底面 is the deformation angle of the bottom surface of the casting in the height direction, 3.95 is the mean value of the measured deviation of the casting height, and 0.0079 is the height deformation coefficient;

[0056] ∠ 顶面 It is the ratio of the deviation between the measured value at the minimum radius and the measured value at the maximum radius in the height direction of the top surface of the casting to T;

[0057] ∠ 底面 It is the ratio of the measured value at the minimum radius in the height direction of the bottom surface of the casting to the measured value at the maximum radius and T.

[0058] In this embodiment, the deformation coefficient in the height direction is calculated through measurement and analysis, which can more accurately optimize the design amount on both sides of the height direction, and ensure that the blanks and processing allowances on both sides of the height direction of the mining machine gear casting are uniform after casting solidification shrinkage deformation. While improving processing efficiency, ensuring the uniformity and symmetry of the blank sizes on both sides of the side T-shaped structure can well solve the problem of uneven weight on both sides of the gear, thereby improving the overall operating capacity and service life of the gear. The height dimension anti-deformation design of the mining machine gear casting in this embodiment is as follows: Figure 3 As shown, the anti-deformation mounting design 310 on the riser side and the anti-deformation mounting design 320 on the non-riser side are not conventional uniform mountings, but asymmetric mounting designs that are fitted according to the casting structure and measured data.

[0059] The anti-deformation design method of radius size may include the following steps:

[0060] S210, such as Figure 2 As shown, a plurality of second measuring points 120 are marked on the arcuate inner surface of the mining machine gear casting. The second measuring points 120 can be evenly spaced and distributed in equal angle increments in the circumferential direction of the mining machine gear casting and in equal height increments in the height direction. A plurality of second measuring points 120 can also be marked in a uniformly spaced and distributed manner on the arcuate outer surface of the mining machine gear casting.

[0061] S220, measuring the radius size of each second measuring point 120, and calculating the deformation value of each second measuring point 120. The calculation formula of the deformation value of the second measuring point 120 is:

[0062] d1=a1'-(b'+c'), d2=a2'-(b'+c')......d m =a m '-(b'+c')...;

[0063] d is the deformation value of the second measuring point 120 , a′ is the radius value of the second measuring point 120 , b′ is the radius design value of the corresponding angle of the second measuring point 120 , and c′ is the radius model deviation value of the corresponding angle of the second measuring point 120 .

[0064] S230, grouping the second measurement points 120 according to different angles, and calculating the average deformation of each group of second measurement points 120. The calculation formula for the average deformation of the second measurement points 120 at the same angle is:

[0065] u=(d1+d2+……+d m ) / m;

[0066] u is the average deformation of the second measuring point 120 at the same angle, d m is the deformation value of the second measuring point 120 at the same angle, and m is the number of the second measuring points 120 at the same angle.

[0067] S240, fitting the deformation mean of the second measuring point 120 at each angle to obtain a radius size inverse deformation fitting formula.

[0068] The formula for the inverse deformation of the radius size is:

[0069] Y=-(6.27+0.004×R-0.41×∠);

[0070] Among them, Y is the anti-deformation value of the casting radius size, 6.27 is the constant coefficient, 0.004 is the radius deformation coefficient, R is the theoretical radius of the casting, 0.41 is the angle deformation coefficient, and ∠ is an arbitrary angle.

[0071] S250, in the process design, the deformation amount opposite to the deformation amount is calculated according to the formula, so as to ensure that the size of the gear ring after the opening deformation meets the tolerance requirements. Figure 4 As shown, the anti-deformation design 210 of the outer diameter and the anti-deformation design 220 of the inner diameter are not conventional uniform designs, but non-uniform designs that are fitted according to the casting structure and measured data.

[0072] The above-mentioned embodiments only express several implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. A method for designing the dimensions of a ring-type structural casting, characterized in that: Including height dimension anti-deformation design and radius dimension anti-deformation design; The height dimension anti-deformation design includes marking a number of first measurement points on the top surface and / or bottom surface of the casting; dividing the total height of the casting equally to find the center line; taking the center line as a reference to obtain the deformation deviation value of each first measurement point and calculating the average deformation deviation value of the first measurement points on the same measurement surface; fitting the average deformation deviation value of the first measurement points on each measurement surface to obtain the height dimension anti-deformation measurement formula; using the height dimension anti-deformation measurement formula to calculate the measurement value of each height value of the casting, and performing the height dimension anti-deformation design of the casting; The radius dimension anti-deformation design marks a number of second measurement points on the inner surface and / or outer surface of the casting, obtains the deformation value of each second measurement point; calculates the deformation mean of the second measurement points at the same angle; fits the deformation mean of the second measurement points at each angle to obtain the radius dimension anti-deformation fitting formula; uses the radius anti-deformation fitting formula to calculate the fitting of each radius value of the casting, and performs the radius dimension anti-deformation design of the casting.

2. The dimension design method of the ring-type structure casting according to claim 1, characterized in that: The calculation formula for the mean deformation value of the first measuring point is: x=(z1+z2+……+z n ) / n; x is the mean value of the deformation deviation of the first measuring point on the same measuring surface, z is the deformation deviation value of the first measuring point on the same measuring surface, and n is the number of the first measuring points on the same measuring surface.

3. The dimension design method of the ring-type structure casting according to claim 2, characterized in that: The calculation formula of the deformation value of the first measuring point is: z n =a n -(b+c); z n is the deformation deviation value of the first measuring point, a n is the deviation between the measured value and the theoretical value of the first measuring point, b is the height design value of the plane corresponding to the first measuring point, and c is the height model deviation value of the plane corresponding to the first measuring point.

4. The dimension design method of the ring-type structure casting according to claim 1, characterized in that: The first measuring points are evenly spaced apart on the top surface and / or the bottom surface of the casting.

5. The dimension design method of the ring-type structure casting according to claim 1, characterized in that: The height dimension anti-deformation pasting amount formula is: and 顶面 =(3.95-0.0079×T×∠ 顶面 )~3.95; and 底面 =3.95~(3.95+0.0079×T×∠ 底面 ); y 顶面 is the design value of the height dimension of the top surface of the casting, 底面 is the design value of the height dimension anti-deformation of the bottom surface of the casting, T is the theoretical width between the minimum radius and the maximum radius in the height direction of the casting, ∠ 顶面 is the deformation angle of the top surface of the casting in the height direction, ∠ 底面 is the deformation angle of the bottom surface of the casting in the height direction, 3.95 is the mean value of the measured deviation of the casting height, and 0.0079 is the height deformation coefficient; ∠ 顶面 It is the ratio of the deviation between the measured value at the minimum radius and the measured value at the maximum radius in the height direction of the top surface of the casting to T; ∠ 底面 It is the ratio of the measured value at the minimum radius in the height direction of the bottom surface of the casting to the measured value at the maximum radius and T.

6. The method for designing the dimensions of a ring-type structural casting according to any one of claims 1 to 5, characterized in that: The calculation formula for the mean deformation value of the second measuring point is: u=(d1+d2+……+d m ) / m; u is the mean deformation of the second measurement point at the same angle, d m is the deformation value of the second measuring point at the same angle, and m is the number of the second measuring points at the same angle.

7. The dimension design method of the ring-type structure casting according to claim 6, characterized in that: The calculation formula of the deformation value of the second measuring point is: d m =a m ’-(b’+c’); d m is the deformation value of the second measuring point, a m ' is the radius value of the second measuring point, b' is the radius design value of the corresponding angle of the second measuring point, and c' is the radius model deviation value of the corresponding angle of the second measuring point.

8. The dimension design method of the ring-type structure casting according to claim 6, characterized in that: The formula for the inverse deformation amount of the radius size is: Y=-(6.27+0.004×R-0.41×∠); Y is the anti-deformation value of the casting radius size, 6.27 is the constant coefficient, 0.004 is the radius deformation coefficient, R is the theoretical radius of the casting, 0.41 is the angle deformation coefficient, and ∠ is an arbitrary angle.

9. The dimension design method of the ring-type structure casting according to claim 6, characterized in that: The second measuring points are evenly spaced apart on the inner surface or the outer surface of the casting.

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