A method for casting forming a rotary cabin with embedded pipelines

Abstract

The application provides a casting forming method of an inner-embedded pipeline rotary cabin component, and steps include: designing a forming metal mold of the cabin component according to structural size characteristics of the cabin component; manufacturing an inner-embedded pipeline according to the inner-embedded pipeline structure of the cabin component; installing the obtained inner-embedded pipeline on the forming metal mold after cleaning; forming an inner-embedded pipeline rotary cabin component rough product by adopting a centrifugal casting process; removing the excess amount of the inner-embedded pipeline rotary cabin component rough product to obtain the inner-embedded pipeline rotary cabin component. The cabin component formed by adopting the scheme of the application significantly improves the metallurgical bonding quality of dissimilar metals, suppresses the interface failure behaviors such as cracks, holes and other interface failures caused by interface wetting, and significantly improves the functional performances such as pressure bearing and heat dissipation without increasing the wall thickness of the component substrate.

Description

Technical Field

[0001] This invention relates to the field of forming technology for internal pipeline rotary cabins, and specifically to a casting forming method for internal pipeline rotary cabins. Background Technology

[0002] In recent years, with the increasing demands for integrated components in high-end equipment, components need to have a closed, highly airtight hollow structure, either partially or entirely, to enable the transmission of media such as gases and liquids or to facilitate rapid heating and cooling of components.

[0003] Existing closed, airtight hollow structural components are mostly formed using welding or splicing processes, but these suffer from high manufacturing costs and complex component structures. In the casting field, closed hollow structures are mostly prepared using sand casting. One method involves pre-embedding independent sand cores in the mold, cleaning the pre-embedded sand cores after casting, and finally obtaining the hollow structure. Another method involves pre-embedding high-strength materials such as stainless steel or ceramic pipes in the mold, allowing them to be directly cast with the component. This fully leverages the lightweight properties of aluminum alloys and the high strength, pressure resistance, and wear resistance of steel and ceramics, achieving both high performance and lightweight components.

[0004] However, the aforementioned method one suffers from problems such as difficulty in cleaning the internal sand core of the hollow structure, low dimensional accuracy, and poor venting, resulting in a single hollow structure, numerous defects such as pores and shrinkage in the pipe wall, large deformation, and poor airtightness. Furthermore, the outer wall thickness of the hollow structure is over 10mm, making it difficult to achieve lightweight components. The aforementioned method two suffers from problems such as difficulty in controlling the shape and positioning of the pre-embedded pipes, and a single pipe structure and location. In addition, due to the poor wettability between the pre-embedded pipes and the molten aluminum alloy, the pre-embedded pipes require cumbersome aluminizing pretreatment processes before casting, and the bonding effect between the pipes and the outer aluminum substrate is poor, easily leading to defects such as cracks and pores. Moreover, this type of process has a complex casting system, is difficult to clean afterward, has a low yield, and high labor and material costs. Summary of the Invention

[0005] At least in order to solve the technical problems mentioned in the background art, the present invention aims to provide a casting method for an internal pipeline rotating cabin component.

[0006] The present invention adopts the following technical solution.

[0007] A casting method for an internally embedded pipeline rotating cabin component, comprising the following steps:

[0008] Step 1: Design the forming metal mold for the cabin components based on the structural dimensional characteristics of the cabin components;

[0009] Step 2: Based on the internal piping structure of the cabin components, fabricate the internal piping.

[0010] Step 3: Clean the obtained embedded pipe and install it on the forming metal mold;

[0011] Step 4: The raw material of the internal pipeline rotating cabin component is formed by centrifugal casting process;

[0012] Step 5: Remove the excess material from the raw material of the embedded pipeline rotary cabin component to obtain the embedded pipeline rotary cabin component.

[0013] Furthermore, the forming metal mold includes: a cylindrical outer mold, a plurality of coaxially arranged segmented combined inner molds fitted on the inner wall of the cylindrical outer mold, cover plates provided at both ends of the cylindrical outer mold, and a heating system and a cooling system provided around the cylindrical outer mold; radially arranged mold positioning holes are provided on the segmented combined inner molds, the mold positioning holes are used to fix and install the embedded pipelines, and the demolding draft angle between the cylindrical outer mold and the segmented combined inner molds is 0.5~2°.

[0014] Furthermore, a positioning support is connected to the embedded pipeline. The positioning support is made of the same material as the embedded pipeline and is used to insert into the positioning hole of the mold. This structure facilitates the precise and stable installation of the embedded pipeline onto the forming metal mold.

[0015] Furthermore, the process of fabricating the embedded pipeline in step 2 is as follows: first, the embedded pipeline blank is preheated, then wound into shape, and then the positioning support is welded on.

[0016] Furthermore, the cleaning process for the embedded pipeline is as follows: First, fix both ends of the embedded pipeline on the clamping fixture and check the airtightness of the embedded pipeline. Then, perform two ultrasonic cleanings. The cleaning temperature is 50~100℃, the ultrasonic frequency is 20~50kHz, and the cleaning time is not less than 15 minutes. After cleaning, place it at 100~150℃ to dry for more than 30 minutes. During the cleaning process, the embedded pipeline is always immersed in the degreasing cleaning solution and does not come into contact with the pool wall.

[0017] Furthermore, step 4 specifically includes:

[0018] Start the centrifugal casting equipment, turn on the heating device of the forming metal mold, and keep it at a temperature of 10-15°C above the melt liquidus line.

[0019] The mold is controlled to rotate at a preset speed. When the mold speed reaches the preset speed, the alloy melt is introduced through the center hole of the cover plate of the cylindrical outer mold, so that it quickly fills the mold along the inner wall.

[0020] After the melt filling is completed, maintain the rotation speed and temperature for 10 to 15 minutes to allow the embedded pipeline to be flushed and impregnated in the alloy melt, and to form a transition layer at the interface between the alloy melt and the embedded pipeline.

[0021] After the melt has filled and been kept at a constant temperature, turn on the cooling device of the forming metal mold to cool the molten metal to 100-200°C below the solidification temperature within 10 minutes, so that the alloy melt can solidify quickly.

[0022] Furthermore, when the embedded pipeline is a ring pipe or a spiral pipe, the number of positioning holes in the mold is selected according to the pipeline's rotation diameter and positioning accuracy, and is generally 2 to 4 times the number of pipeline rotations.

[0023] Beneficial effects: The cabin components formed using the scheme of this invention significantly improve the metallurgical bonding quality of dissimilar metals, suppress interface failure behaviors such as cracks and voids caused by interface wetting, and increase the bonding strength between the pipeline and the substrate interface by more than 200% compared with traditional processes. Without increasing the thickness of the component substrate wall, it significantly improves the pressure-bearing and heat dissipation performance. The combined metal mold + multi-point support precise positioning scheme of this invention effectively solves the problem of pipeline deviation from the predetermined position caused by stress rebound at high temperatures and deformation under high-speed molten scouring, significantly improving the spatial positioning accuracy of the pipeline, with a positioning accuracy of ±0. Within 0.3mm, it represents a significant improvement over sand casting; combining the treatment of embedded pipelines with centrifugal casting process eliminates cumbersome procedures such as aluminizing pretreatment before casting with dissimilar metal inlays, while avoiding repeated shaping and molding of pipelines, greatly reducing the difficulty of positioning pipelines inside cabin components, and realizing the efficient production of rotary aluminum alloy components with embedded pipelines, with production efficiency more than doubled compared to traditional sand casting; this solution enhances the diversity of pipeline structures, not only suitable for traditional single ring structures, but also for complex and diverse structures such as multi-segment independent pipelines and continuous spiral pipelines, which can meet the forming requirements of various embedded tube pressure-resistant and heat-dissipating structures. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the forming metal mold in Example 1;

[0025] Figure 2 This is a schematic diagram of the embedded pipeline and the forming metal mold after assembly in Example 1;

[0026] Figure 3 This is a schematic diagram of the internal pipeline rotating cabin component in Example 1;

[0027] Figure 4 This is a schematic diagram of the embedded pipeline in Example 2;

[0028] Figure 5 This is a schematic diagram of the embedded pipeline and the forming metal mold after assembly in Example 2;

[0029] Figure 6 This is a schematic diagram of the internal pipeline rotating cabin component in Example 2;

[0030] Figure 7 This is a schematic diagram of the cross-section of the internal pipeline rotating cabin component in Example 2; Detailed Implementation

[0031] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example

[0032] Combination Figures 1 to 3 As shown, a casting method for an internally embedded pipeline rotary cabin component 12 is disclosed. The main body of the internally embedded pipeline rotary cabin component 12 is a cylindrical structure with an outer wall diameter of Φ500mm. The material is ZL114A aluminum alloy with a wall thickness of 10mm. The internally embedded pipeline 8 is made of stainless steel with a diameter of 3mm and is spirally distributed along the end face of the component. It is mainly used for the circulation and transportation of hot and cold media, realizing the functions of rapid cooling and heating of the component. The method includes the following steps:

[0033] Step 1: Design metal molds for forming cabin components based on the structural dimensional characteristics of the cabin components;

[0034] Specifically:

[0035] Based on the structural dimensions and functional characteristics of the embedded pipeline rotating cabin component 10, a casting blank is designed, with a 5mm allowance on the end face, inner side and outer side of the component.

[0036] The designed forming metal mold includes: a cylindrical outer mold 5, with multiple coaxially arranged segmented combined inner molds 6 fitted on the inner wall of the cylindrical outer mold 5; cover plates 3 are provided at both ends of the cylindrical outer mold 5, and end face positioning holes 2 are provided on the cover plates 3; a heating system 1 and a cooling system are provided around the cylindrical outer mold 5; mold positioning holes 4 are provided radially on the segmented combined inner molds 6; positioning holes 2 and positioning pins 7 are provided on the end caps 3 at both ends of the mold; the positioning holes 2 and positioning pins 7 cooperate to connect the ends of the embedded pipes 8; the mold positioning holes 4 are used to fix and install the embedded pipes 8; the draft angle between the cylindrical outer mold 5 and the segmented combined inner molds 6 is 1.5°; a positioning support 9 is connected to the embedded pipes 8, the positioning support 9 is made of the same material as the embedded pipes 8, the positioning support 9 is used to be inserted into the mold positioning holes 4, the positioning support 9 is formed by welding 2mm stainless steel wire, and the positioning support 9 is linearly distributed along 1 / 4 of the circumference of the spiral pipe;

[0037] Step 2: Based on the internal piping structure of the cabin components, fabricate internal piping 8; specifically:

[0038] First, preheat the blank of the embedded pipeline 8 (3mm stainless steel straight pipe is placed at 300℃ for 0.5h preheating), then wind it into shape, and then weld the positioning support 9. After welding, check the shape, size, surface condition, airtightness of the embedded pipeline 8, as well as the installation of the positioning support 9, and correct the shape of the parts with large deviations, and repair the welding of the positioning support 9 where the welding is not firm enough.

[0039] Step 3: After cleaning the obtained embedded pipe 8, install it on the forming metal mold; specifically:

[0040] First, fix both ends of the embedded pipeline 8 to the clamping fixture, and then perform ultrasonic cleaning. The cleaning temperature is 50℃, the ultrasonic frequency is 50kHz, and the cleaning time is 30min. After cleaning, place it at 120℃ for drying for 30min. During the cleaning process, the embedded pipeline is always immersed in the degreasing cleaning solution and does not come into contact with the pool wall.

[0041] The forming metal mold, the embedded pipeline 8 and the supporting devices are assembled in sequence. During the installation process, the positioning support 9 on the embedded pipeline 8 is matched with the mold positioning hole 4 of the mold to complete the positioning of the embedded pipeline 8, and high temperature coating is sprayed into the inner cavity of the forming metal mold.

[0042] Step 4: Use centrifugal casting process to form 10 rough parts of the internal pipeline rotating cabin component;

[0043] ZL114A aluminum alloy melt was prepared and held at 680℃ for later use.

[0044] Start the horizontal centrifugal casting equipment, turn on the heating device of the forming metal mold, and keep it warm when the temperature of the forming metal mold reaches 560℃;

[0045] The rotational speed of the forming metal mold is calculated using the centrifugal casting principle formula. When the mold rotational speed reaches the calculated value (680 r / min), the alloy melt is introduced through the central hole of the cover plate 3 of the cylindrical outer mold 5, so that the melt quickly fills the mold along the inner wall of the mold.

[0046] After the melt filling is completed, keep it at a constant temperature for 15 minutes to allow the embedded pipeline 8 to be flushed and impregnated in the alloy melt, and to form a transition layer at the interface between the alloy melt and the embedded pipeline 8.

[0047] The cooling system of the forming metal mold is activated to reduce the mold temperature to 300°C within 10 minutes, allowing the alloy melt to cool and solidify rapidly, thus completing the component forming.

[0048] Step 5: Remove the excess material of the inner pipeline rotary cabin component 10 to obtain the inner pipeline rotary cabin component 10.

[0049] In this embodiment, the tensile strength of the embedded pipeline rotating cabin component 10 reaches more than 330 MPa, the elongation reaches more than 3%, and the bonding strength between the internal pipeline and the substrate reaches more than 120 MPa. Example

[0050] Combination Figures 4 to 7 As shown, a casting method for an internally embedded pipeline rotary cabin component 10 is disclosed. The main body of the internally embedded pipeline rotary cabin component 10 is a conical rotary structure with a large end outer wall diameter of 330 mm. The material is ZL205A aluminum alloy, and the main body wall thickness is 5 mm. The pre-embedded pipeline 8 is made of stainless steel, with a diameter of 2 mm, and is distributed near the large and small ends of the component, with a semi-circular shape. The method includes the following steps:

[0051] Step 1: Design the forming metal mold for the cabin components based on the structural dimensional characteristics of the cabin components;

[0052] Specifically:

[0053] Based on the structural dimensions and functional characteristics of the embedded pipeline rotating cabin component 10, a casting blank is designed, with a 6mm allowance on the end face, inner side and outer side of the component.

[0054] The designed forming metal mold includes: a cylindrical outer mold 5, with multiple coaxially arranged segmented combined inner molds 6 fitted on the inner wall of the cylindrical outer mold 5, cover plates 3 at both ends of the cylindrical outer mold 5, and a heating system 1 and a cooling system arranged around the cylindrical outer mold 5; radially arranged mold positioning holes 4 are provided on the segmented combined inner molds 6, which are used to fix and install the embedded pipeline 8, and the demolding draft angle between the cylindrical outer mold 5 and the segmented combined inner molds 6 is 1°; positioning supports 9 are connected to the embedded pipeline 8, the material of the positioning supports 9 is the same as that of the embedded pipeline 8, the positioning supports 9 are used to be inserted into the mold positioning holes 4, and the positioning supports 9 are formed by welding 2mm stainless steel wire, with one positioning support 9 distributed at the center of the semi-circular pipeline;

[0055] Step 2: Based on the internal piping structure of the cabin components, fabricate internal piping 8; specifically:

[0056] First, preheat the blank of the embedded pipeline 8 (place the 2mm stainless steel straight pipe at 200℃ for 0.5h). Then, use a pipe bender to wind it into a semi-circle with straight sections at both ends. Then, weld the positioning support 9 at the center of the outer arc of the wound stainless steel pipeline. After welding, check the shape, size, surface condition, airtightness of the embedded pipeline 8, as well as the installation of the positioning support 9. Correct the shape of the parts with large deviations and repair the welding of the positioning support 9 where the welding is not firm enough.

[0057] Step 3: After cleaning the obtained embedded pipe 8, install it on the forming metal mold; specifically:

[0058] First, fix both ends of the embedded pipeline 8 on the clamping fixture and then perform ultrasonic cleaning. The cleaning temperature is 50℃, the ultrasonic frequency is 45kHz, and the cleaning time is 20min. After cleaning, place it at 120℃ to dry for 30min. During the cleaning process, the embedded pipeline 8 is always immersed in the degreasing cleaning solution and does not come into contact with the pool wall.

[0059] The forming metal mold, the embedded pipeline 8 and the supporting devices are assembled in sequence. During the installation process, the straight sections at both ends of the embedded pipeline 8 and the positioning support 9 are matched one by one with the mold positioning holes 4 of the mold to complete the positioning of the embedded pipeline 8. High temperature coating is sprayed into the inner cavity of the forming metal mold.

[0060] Step 4: Use centrifugal casting process to form 10 rough parts of the internal pipeline rotating cabin component;

[0061] ZL205A aluminum alloy melt was prepared and held at 685℃ for later use;

[0062] Start the centrifugal casting equipment, turn on the heating device of the forming metal mold, and keep it at 570℃.

[0063] The rotational speed of the forming metal mold is calculated using the formula of vertical centrifugal casting principle. When the mold rotational speed reaches the calculated value (560 r / min), the alloy melt is introduced through the central hole of the cover plate 3 of the cylindrical outer mold 5, so that the melt quickly fills the mold along the inner wall of the mold.

[0064] After the melt filling is completed, keep it at a constant temperature for 15 minutes to allow the embedded pipeline 8 to be flushed and impregnated in the alloy melt, and to form a transition layer at the interface between the alloy melt and the embedded pipeline 8.

[0065] The cooling system of the forming metal mold is activated to reduce the mold temperature to 320°C within 10 minutes, allowing the alloy melt to cool and solidify rapidly, thus completing the component forming.

[0066] Step 5: Remove the excess material of the inner pipeline rotary cabin component 10 to obtain the inner pipeline rotary cabin component 10.

[0067] In this embodiment, the local pressure resistance of the internal pipeline rotating cabin component reaches 12MPa or higher, the outer wall thickness of the internal pipeline is less than 5mm, and the local weight reduction exceeds 100%.

Claims

1. A casting forming method for an internally embedded pipeline rotating cabin component, characterized in that the steps include... include: Step 1: Design the forming metal mold for the cabin components based on the structural dimensional characteristics of the cabin components; Step 2: Based on the internal piping structure of the cabin components, fabricate the internal piping. Step 3: Clean the obtained embedded pipe and install it on the forming metal mold; Step 4: The raw material of the internal pipeline rotating cabin component is formed by centrifugal casting process; Step 5: Remove the excess material from the raw material of the embedded pipeline rotary cabin component to obtain the embedded pipeline rotary cabin component. The forming metal mold includes: a cylindrical outer mold, with multiple coaxially arranged segmented combined inner molds fitted on the inner wall of the cylindrical outer mold; cover plates are provided at both ends of the cylindrical outer mold; a heating system and a cooling system are provided around the cylindrical outer mold; radially arranged mold positioning holes are provided on the segmented combined inner molds for fixing and installing embedded pipelines; the draft angle between the cylindrical outer mold and the segmented combined inner molds is 0.5~2°; a positioning support is connected to the embedded pipeline, the material of the positioning support is the same as the material of the embedded pipeline, and the positioning support is used to be inserted into the positioning hole of the mold.

2. The casting forming method according to claim 1, characterized in that, The process for fabricating the embedded pipeline in step 2 is as follows: first, preheat the embedded pipeline blank, then wind it into shape, and then weld the positioning support.

3. The casting forming method according to claim 1, characterized in that, The cleaning process for the embedded pipeline is as follows: First, fix both ends of the embedded pipeline on the clamping fixture and check the airtightness of the embedded pipeline. Then, perform two ultrasonic cleanings. The cleaning temperature is 50~100℃, the ultrasonic frequency is 20~50kHz, and the cleaning time is not less than 15 minutes. After cleaning, place it at 100~150℃ to dry for more than 30 minutes. During the cleaning process, the embedded pipeline is always immersed in the degreasing cleaning solution and does not come into contact with the pool wall.

4. The casting forming method according to any one of claims 1-3, characterized in that, Step 4 specifically includes: Start the centrifugal casting equipment, turn on the heating device of the forming metal mold, and keep it at a temperature of 10-15°C above the melt liquidus line. The mold is controlled to rotate at a preset speed. When the mold speed reaches the preset speed, the alloy melt is introduced through the center hole of the cover plate of the cylindrical outer mold, so that it quickly fills the mold along the inner wall. After the melt filling is completed, maintain the rotation speed and temperature for 10 to 15 minutes to allow the embedded pipeline to be flushed and impregnated in the alloy melt, and to form a transition layer at the interface between the alloy melt and the embedded pipeline. After the melt has filled and been kept at a constant temperature, turn on the cooling device of the forming metal mold to cool the molten metal to 100-200°C below the solidification temperature within 10 minutes, so that the alloy melt can solidify quickly.

5. The casting forming method according to claim 4, characterized in that, When the embedded pipeline is a ring pipe or a spiral pipe, the number of positioning holes in the mold is selected according to the pipeline's rotation diameter and positioning accuracy, and is generally 2 to 4 times the number of pipeline rotations.

Images