Coloring pouring device for improving flowmeter products and use method of coloring pouring device

Abstract

The invention discloses a coloring pouring device for improving flowmeter products and a using method of the coloring pouring device, and belongs to the technical field of precision investment casting, the device comprises a top riser, a cross gate, vertical runners and a horizontal sprue gate which are communicated with one another, the top riser is vertically arranged at the top of the cross gate, the vertical runners are arranged at the bottoms of the two sides of the cross gate, and the horizontal sprue gate is arranged at the bottom of the cross gate. Horizontal sprue gates are symmetrically formed in the inner side of the lower end of the vertical pouring gate, the height range of the horizontal sprue gates is 25-35 cm, each horizontal sprue gate is of a reduction structure, the cross section of each horizontal sprue gate is rectangular, and the ratio of the modulus of a casting hot spot to the modulus of an inner sprue to the modulus of a casting head is (1-1.2): (1.5-1.6): (1.75-1.95). Compared with the prior art, the method has the advantages that the production process is simplified, the mold manufacturing and production cost is reduced, the material consumption is reduced, the resource utilization rate is increased, the defect of poor coloring of the surface of the casting is effectively eliminated, and the nondestructive PT detection qualification rate after the stainless steel flowmeter is machined is remarkably increased.

Description

Technical Field

[0001] The present invention belongs to the technical field of investment casting, and in particular relates to a coloring pouring device for improving flow meter products and a method of using the same. Background Art

[0002] In the investment casting industry, stainless steel flowmeters are essential products, and their quality plays a key role in the accuracy and stability of flow measurement. Nondestructive penetrant testing (PT), a common method for detecting surface defects on castings, ensures product quality. However, the current pass rate for post-processing NDT testing of stainless steel flowmeters is low, increasing production costs and reducing efficiency and market competitiveness.

[0003] The traditional technology to improve the pass rate of non-destructive PT testing of stainless steel flowmeters is mainly to increase the feeding cross-sectional area of ​​the hot zone to enhance the feeding effect, so that the casting solidifies sequentially during the cooling process, thereby eliminating defective areas and achieving the purpose of color testing. However, this technology has the following obvious disadvantages: 1. High process complexity: Increasing the feeding cross-sectional area of ​​the hot zone requires complex design and adjustment of the mold structure, increasing the difficulty and cost of mold manufacturing. At the same time, in the actual production process, the control requirements for process parameters are also very strict. The slightest deviation may lead to poor feeding effect.

[0004] 2. Low production efficiency: Increasing the feeding cross-sectional area increases the overall size and weight of the casting, which prolongs the cooling time and reduces production efficiency. In addition, the complex process also increases the production cycle, making it difficult to meet the needs of large-scale production.

[0005] 3. Serious material waste: In order to achieve the purpose of increasing shrinkage compensation, it is often necessary to set larger risers and subsidies on the casting, which not only increases the consumption of metal materials, but also requires the removal of these excess parts in subsequent processing, further increasing processing costs and material waste.

[0006] 4. Limited effect: Although increasing the feeding cross-sectional area can improve the internal quality of the casting to a certain extent, it is still difficult to completely eliminate defects in some special parts, such as tiny pores and cracks, resulting in limited effect in improving the pass rate of non-destructive PT testing.

[0007] Therefore, how to design a coloring pouring device and a method of using the same to improve flow meter products and solve the above technical problems has long troubled technicians in this field. Summary of the Invention

[0008] In view of the above technical problems, the application provides a coloring pouring device for improving flow meter products and a use method thereof, and the above problems are solved by the following technical means. The coloring pouring device for improving flow meter products comprises a top riser, a horizontal gate, a vertical gate and a horizontal pouring gate which are communicated with each other, wherein the top riser is vertically arranged at the top of the horizontal gate, vertical gates are arranged at the bottom of the two sides of the horizontal gate, horizontal pouring gates are symmetrically arranged at the inner side of the lower end of the vertical gate, the height of the horizontal pouring gate ranges from 25 cm to 35 cm, the horizontal pouring gate has a taper structure and a rectangular cross section, and the ratio of the casting hot section modulus, the ingate modulus and the pouring gate modulus is 1-1.2:1.5-1.6:1.75-1.95.

[0009] Preferably, a wax rod for wax and slag removal is vertically arranged at the lower side of the middle part of the horizontal gate, one end of the wax rod is connected with the casting, and the other end of the wax rod is connected with the gate.

[0010] Preferably, the outlet of the horizontal pouring gate is opposite to the outer sensor table of the flow meter product, and the bottom of the wax rod is opposite to the top surface of the flow meter product, wherein the main body of the flow meter product is a cylindrical shell structure, a triangular prism is horizontally arranged in the cylindrical shell structure, and a plurality of sensor tables are symmetrically arranged on the outer part of the cylindrical shell structure, and the sensor tables on the outer part are connected with the triangular prism in the inner part.

[0011] Preferably, the use method comprises the following steps: 1) wax mold manufacturing: common paraffin and stearic acid are mixed at a ratio of 50:50, the melting temperature is 70-80 DEG C, the paste-like wax material is pressed into the mold at a temperature of 51-61 DEG C and an injection pressure of 1.8-2.2 MPa, the pressure is maintained at 0.3-0.4 MPa, and the wax mold is trimmed after cooling and setting; 2) mold group welding: the wax mold is welded on the wax rod of the pouring device according to the combined drawing to form a tree structure, the distance between the wax molds is 15-30 mm, the top end of the gate rod is reserved by 80-100 mm, and the welding temperature is 150-200 DEG C.

[0012] 3) shell preparation: 80-120 mesh zirconium sand is scattered to form a surface layer, and 16-30 mesh mullite sand or sagger sand is scattered to form a reinforcing layer; 4) dewaxing and baking: steam dewaxing is adopted at a pressure of 0.6-0.8 MPa, the mold shell is inverted and cleaned after dewaxing, the mold shell is baked at 900-950 DEG C for 1-1.5 hours to remove residual wax material and enhance the strength; 5) Melting and pouring: After the steel is melted in a medium frequency induction furnace, the molten steel is poured into the calcined mold shell at a temperature range of 1560-1580°C. The calcination temperature is maintained at 1000-1050°C for 60-90 minutes. 6) Cleaning and finishing: Hammer or vibrate the sheller to separate the shell, cut off the pouring head, and trim the protruding part of the chill iron.

[0013] Preferably, the cleaning and finishing steps further include the following steps: 6.1) Defect Analysis: After conducting non-destructive PT testing on flow meter products, analyze the test results and determine the location and characteristics of the poorly colored areas; 6.2) Gate Removal: After casting and cooling, the mold is shot blasted in a shot blasting machine for 15 to 30 minutes to remove the residual mold shell on the surface. Based on the results of the defect analysis, the gate of the poorly colored area is removed using a cutter, and the cut gate area is polished to the required range of the drawing using a belt sander. 6.3) Post-processing: After the gate is removed, the casting is ground and polished to ensure the flatness and smoothness of the casting surface and improve the accuracy of non-destructive PT testing.

[0014] The coloring pouring device for improving flow meter products and the use method thereof of the present invention have the following beneficial effects: 1) In this method, a wax rod is used to replace the traditional top pouring gate, and only the horizontal pouring gate is retained. This can reduce the amount of molten steel at the top pouring gate by about 0.4 kg, improve the process yield, and reduce the material cost of the smelting process.

[0015] 2) After removing the top sprue in this method, it was unexpectedly found that this part could cool faster than the gate. Removing the gate at this location significantly improved the yield rate, simplified the assembly difficulty, and shortened the time for cutting and polishing the gate.

[0016] 3) This method uses a new casting device to allow the casting to solidify sequentially, which can reduce hot spots in important parts, shorten the solidification time (cool down later than the gate part), and make the colored part dense enough to meet the standards for non-destructive PT testing. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the technical solution of the present invention, the following is a brief introduction to the drawings required for use in the implementation. Obviously, the drawings described below are only some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0018] Figure 1 It is a schematic diagram of the pouring device of the present invention; FIG2 is a schematic structural diagram of a flow meter product of the present invention; FIG3 is a schematic diagram of the internal structure of a flow meter product of the present invention; FIG4 is a schematic diagram of an application of the present invention.

[0019] Among them, 1-top riser, 2-horizontal runner, 3-vertical runner, 4-horizontal pouring gate, 5-wax rod, 6-flow meter products, 7-sensor table, 8-triangular prism. DETAILED DESCRIPTION

[0020] In the description of the present invention, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. The terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0021] The present invention will be described in detail below with reference to the accompanying drawings.

[0022] like Figure 1 As shown in Figure 4, the coloring pouring device for improving flow meter products includes a top riser 1, a horizontal runner 2, a vertical runner 3 and a horizontal pouring gate 4 that are interconnected, wherein: the top riser 1 is vertically arranged at the top of the horizontal runner 2, vertical runners 3 are arranged at the bottom of both sides of the horizontal runner 2, and horizontal pouring gates 4 are symmetrically arranged on the inner side of the lower end of the vertical runner 3; the height range of the horizontal pouring gate 4 is 25cm to 35cm; the horizontal pouring gate 4 is a reduced structure, and the cross-section of the horizontal pouring gate 4 is rectangular; the ratio of the casting hot section modulus: the inner gate modulus: the pouring gate modulus = 1~1.2: 1.5~1.6: 1.75~1.95.

[0023] In specific applications, the horizontal pouring gate outlet cross-section can be 35mm*31mm, and the horizontal pouring gate inlet cross-section range can be 41mm*47mm. In addition, the casting hot pitch circle diameter is Φ20mm, the hot pitch circle diameter of the ingate is Φ30mm, and the hot pitch circle diameter of the pouring riser is Φ34mm.

[0024] In the figure, a wax stick 5 for removing wax and slag is vertically arranged at the lower middle part of the horizontal runner 2. One end of the wax stick 5 is connected to the casting, and the other end of the wax stick 5 is connected to the runner. Specifically, the diameter of the wax stick 5 can be Φ10mm and the length can be 43mm. The wax stick is connected to the casting on one side and the runner on the other side to play the role of removing wax and slag.

[0025] In the figure, the outlet of the horizontal pouring port 4 faces the outer sensor platform 7 of the flow meter product 6, and the bottom of the wax stick 5 faces the top surface of the flow meter product 6, wherein: the main body of the flow meter product 6 is a cylindrical shell structure, and a triangular prism 8 is horizontally arranged inside the cylindrical shell structure. A plurality of sensor platforms 7 are symmetrically arranged on the outside of the cylindrical shell structure, and the external sensor platforms 7 are interconnected with the internal triangular prisms 8. Specifically, the structure of this series of flow meters is mainly a barrel-mounted structure, with a triangular prism added in the middle of the barrel, and a sensor platform is arranged outside the ring, and the sensor platform is connected to the middle triangular prism. The triangular prism is used for flow detection, and a support is installed at the sensor platform position to place the sensor.

[0026] In this embodiment, the device includes the following steps: 1) Wax pattern manufacturing: Paraffin wax and stearic acid are usually mixed in a ratio of 50:50, with a melting temperature of 70-80°C. The wax paste is pressed into the mold at a temperature range of 51-61°C at an injection pressure of 1.8-2.2 MPa, and the pressure is maintained at 0.3-0.4 MPa. After the wax pattern is cooled and shaped, the flash and concave edges are trimmed; 2) Module welding: Weld the wax mold to the wax rod 5 of the pouring device according to the assembly drawing to form a tree structure. The wax mold spacing is 15~30mm, and 80~100mm is reserved at the top of the gate rod. The welding temperature is 150~200℃.

[0027] 3) Shell preparation: Sprinkle 80-120 mesh zircon sand to form the surface layer, and then sprinkle 16-30 mesh mullite sand or sagger sand to form the reinforcement layer; 4) Dewaxing and calcining: Use steam dewaxing at a pressure of 0.6~0.8MPa. After dewaxing, the mold shell is inverted for cleaning and calcined at 900~950℃ for 1~1.5 hours to remove residual wax and enhance strength. 5) Melting and pouring: After the steel is melted in a medium frequency induction furnace, the molten steel is poured into the calcined mold shell at a temperature range of 1560-1580°C. The calcination temperature is maintained at 1000-1050°C for 60-90 minutes. 6) Cleaning and finishing: Hammer or vibrate the sheller to separate the shell, cut off the pouring head, and trim the protruding part of the chill iron.

[0028] It should be further explained that the cleaning and finishing steps also include the following steps: 6.1) Defect Analysis: After conducting non-destructive PT testing on flow meter products 6, analyze the test results and determine the location and characteristics of the poorly colored areas; 6.2) Gate Removal: After casting and cooling, the mold is shot blasted in a shot blasting machine for 15 to 30 minutes to remove the residual mold shell on the surface. Based on the results of the defect analysis, the gate of the poorly colored area is removed using a cutter, and the cut gate area is polished to the required range of the drawing using a belt sander. 6.3) Post-processing: After the gate is removed, the casting is ground and polished to ensure the flatness and smoothness of the casting surface and improve the accuracy of non-destructive PT testing.

[0029] In practical application, this method uses a wax stick 5 to replace the traditional top pouring gate, retaining only the horizontal pouring gate 4. This reduces the amount of molten steel at the top pouring gate by approximately 0.4 kg, improving process yield and reducing material costs in the smelting process. Removing the top pouring gate unexpectedly revealed that this area cools faster than the pouring gate. Removing the pouring gate at this location significantly improves yield, simplifies assembly work, and shortens the time required to cut and polish the pouring gate. This method utilizes a novel casting device to achieve sequential solidification of the casting, reducing hot spots in key areas and shortening solidification time (cooling later than the pouring gate), resulting in a denser structure in the colored area that meets the standards for non-destructive PT testing.

[0030] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A coloring pouring device for improving flow meter products, characterized in that: It includes interconnected top riser, horizontal runner, vertical runner and horizontal pouring gate, among which: The top riser is vertically arranged on the top of the horizontal runner, vertical runners are arranged at the bottom of both sides of the horizontal runner, and horizontal pouring gates are symmetrically arranged on the inner side of the lower end of the vertical runner; The height of the horizontal pouring port ranges from 25 cm to 35 cm; The horizontal pouring gate is a reduced structure, and the cross section of the horizontal pouring gate is rectangular; The ratio of casting hot section modulus: ingate modulus: pouring and riser modulus is 1~1.2:1.5~1.6:1.75~1.

95.

2. The coloring pouring device for improving flow meter products according to claim 1, characterized in that: A wax rod for removing wax and slag is vertically arranged at the lower middle part of the horizontal runner, one end of the wax rod is connected to the casting, and the other end of the wax rod is connected to the runner.

3. The coloring pouring device for improving flow meter products according to claim 2, characterized in that: The outlet of the horizontal pouring port faces the outer sensor platform of the flow meter product, and the bottom of the wax stick faces the top surface of the flow meter product, wherein: The main body of the flow meter product is a cylindrical shell structure, wherein a triangular prism is horizontally arranged inside the cylindrical shell structure, and a plurality of sensor platforms are symmetrically arranged outside the cylindrical shell structure, and the external sensor platforms are interconnected with the internal triangular prisms.

4. The coloring pouring device for improving flow meter products according to claim 1, characterized in that: The following steps are included: 1) Wax pattern manufacturing: Paraffin wax and stearic acid are usually mixed in a ratio of 50:50, with a melting temperature of 70-80°C. The wax paste is pressed into the mold at a temperature range of 51-61°C at an injection pressure of 1.8-2.2 MPa, and the pressure is maintained at 0.3-0.4 MPa. After the wax pattern is cooled and shaped, the flash and concave edges are trimmed; 2) Module welding: Weld the wax mold to the wax rod of the pouring device according to the assembly drawing to form a tree-like structure. The wax mold spacing is 15~30mm, and 80~100mm is reserved at the top of the gate rod. The welding temperature is 150~200℃. 3) Shell preparation: Sprinkle 80-120 mesh zircon sand to form the surface layer, and then sprinkle 16-30 mesh mullite sand or sagger sand to form the reinforcement layer; 4) Dewaxing and calcining: Use steam dewaxing at a pressure of 0.6~0.8MPa. After dewaxing, the mold shell is inverted for cleaning and calcined at 900~950℃ for 1~1.5 hours to remove residual wax and enhance strength. 5) Melting and pouring: After the steel is melted in a medium frequency induction furnace, the molten steel is poured into the calcined mold shell at a temperature range of 1560-1580°C. The calcination temperature is maintained at 1000-1050°C for 60-90 minutes. 6) Cleaning and finishing: Hammer or vibrate the sheller to separate the shell, cut off the pouring head, and trim the protruding part of the chill iron.

5. The coloring pouring device for improving flow meter products according to claim 4, characterized in that: The cleaning and finishing steps also include the following steps: 6.1) Defect Analysis: After conducting non-destructive PT testing on flow meter products, analyze the test results and determine the location and characteristics of the poorly colored areas; 6.2) Gate Removal: After casting and cooling, the mold is shot blasted in a shot blasting machine for 15 to 30 minutes to remove the residual mold shell on the surface. Based on the results of the defect analysis, the gate of the poorly colored area is removed using a cutter, and the cut gate area is polished to the required range of the drawing using a belt sander. 6.3) Post-processing: After the gate is removed, the casting is ground and polished to ensure the flatness and smoothness of the casting surface and improve the accuracy of non-destructive PT testing.

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