Water jet cutting process for manufacturing large frame casting based on wide and thick continuous casting billet

Abstract

The invention belongs to the technical field of casting and machining, and particularly provides a water jet cutting process for manufacturing a large frame casting based on wide and thick continuous casting billets, which comprises the following steps: S1, pretreating the wide and thick continuous casting billets; s2, a high-pressure water jet cutter is used for roughly cutting the outline of the rolling mill housing; s3, monitoring is conducted, a cutting route is corrected and finished, the allowance reserved during rough cutting is cut off, and finish machining of the rolling mill housing outline is completed; s4, checking the profile of the rolling mill housing after finish machining, if the profile is not qualified, repeating the step S3 until the profile is qualified, and finishing manufacturing of the rolling mill housing; the problems that an existing large frame structure casting in a complex shape is low in cutting precision, cracks, roughness and deformation are prone to occurring on the surface of the casting, the cutting quality and cutting efficiency are low, and the production cost is high are solved. Precise cutting of large frame structure castings in complex shapes is achieved, deformation and cracks caused by heat influence are effectively avoided, the working efficiency is high, batch production is achieved, the cost is reduced, and the cutting precision is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of casting and mechanical processing, and in particular relates to a water jet cutting process for manufacturing a large frame casting based on a wide and thick continuous casting billet. Background Art

[0002] Large-scale frame structure castings, especially steel castings and alloy steel castings used in machinery, automobiles, aviation, energy and other fields, usually require high dimensional accuracy and good surface quality. Traditional cutting processes, such as mechanical sawing, laser cutting and plasma cutting, often cause cracks, roughness and even deformation on the surface of the casting, affecting the mechanical properties and appearance quality of the casting. Especially when processing wide and thick continuous casting billets, these traditional processes will have an important impact on production efficiency and casting quality. High-pressure water jet cutting, as an advanced cold cutting technology, can effectively avoid deformation and cracks caused by thermal effects, and has high cutting accuracy, so it is increasingly used in the foundry industry. However, there are still some difficulties in the efficient application of water jet technology on large-sized and thick cast steel billets.

[0003] The Chinese patent document with the publication number CN109396325A discloses a large steel casting net forming technology, including the establishment of a three-dimensional model of the pattern - computer software layer-by-layer slicing, 3D printing of the casting pattern - embedding the box, pouring, dropping the box hanging parts - sawing machine cutting the riser - water jet cutting other process accessories - shot blasting and sand blasting, and finished product process steps, which can obtain a high-strength casting cavity with a smooth inner surface. The casting cavity formed by the ceramsite sand printing will not expand and deform due to high temperature. The molten steel is solidified and cooled in the casting to generate a casting with high dimensional accuracy and clean appearance; the ceramsite sand cavity made is far lower than the refractory limit of the ceramsite sand in the cavity, and the molten steel is in contact with the casting surface. The castings in this document are mold castings, and the molding and processing procedures of the mold castings are cumbersome, the quality is not high, the cost is high, and it is impossible to achieve mass production; this document solves the problem of sand sticking to steel castings, and can only guarantee the accuracy of the steel saw cutting straight lines. For the frame structure with complex shapes, due to its complex lines, this document cannot guarantee the cutting quality. Summary of the invention

[0004] The present invention provides a water jet cutting process for producing large frame castings based on wide and thick continuous casting billets, with the purpose of overcoming the problems of low cutting accuracy of large frame structure castings with complex shapes in the prior art, which easily leads to cracks, roughness and even deformation on the surface of the castings, affecting the mechanical properties and appearance quality of the castings, low cutting efficiency and high production costs.

[0005] To this end, the present invention provides a water jet cutting process for manufacturing large frame castings based on wide and thick continuous casting billets, comprising the following steps: S1. Pretreatment of wide and thick continuous casting billets; S2. Use a high-pressure water jet to perform rough cutting of the mill arch profile on the pre-treated wide and thick continuous casting billet; S3, real-time monitoring of the rough cutting process of the mill arch profile, and correction and finishing of the cutting route of the high-pressure water jet, cutting off the margin reserved during the rough cutting, and completing the fine processing of the mill arch profile; S4, inspect the mill arch profile after fine machining, and when the inspection is qualified, complete the cutting; when the inspection is unqualified, repeat step S3 until the inspection is qualified and complete the cutting.

[0006] Preferably, the pretreatment includes mechanical brushing, ultrasonic cleaning, grinding or polishing.

[0007] Preferably, when the rough cutting of the mill arch profile is performed in step S2, holes are firstly processed on the four corners of the wide and thick continuous casting billet after pretreatment, and then the rough cutting is performed according to the three-dimensional model.

[0008] Preferably, during the rough cutting, two high-pressure water jets are used for alternating cutting, wherein the first high-pressure water jet is used for cutting and marking, and the second high-pressure water jet is used for complete cutting.

[0009] Preferably, when the first high-pressure water jet is used for cutting and marking, its preset water flow pressure only needs to achieve a cutting depth of more than half the thickness of the wide and thick continuous casting billet.

[0010] Preferably, the two high-pressure water jets are both provided with pressure sensors.

[0011] Preferably, the cutting is performed by pre-mixed abrasive water jet cutting.

[0012] Preferably, the abrasive in the pre-mixed abrasive water jet cutting is aluminum oxide with a particle size range of 120 mesh to 200 mesh.

[0013] Preferably, the cutting is performed using a cutting tool, which is mounted on a workbench base. A water tank is mounted below the workbench base, and the workbench base is hollowed out. During cutting, water carries the chips through the hollowed-out workbench base into the water tank.

[0014] Preferably, a magnetic coil is provided in the water tank.

[0015] Beneficial effects of the present invention: 1. The water jet cutting process for making large frame castings based on wide and thick continuous casting billets provided by the present invention comprises the following steps: S1, pre-treating the wide and thick continuous casting billets; S2, using a high-pressure water jet to perform rough cutting of the mill arch contour on the pre-treated wide and thick continuous casting billets; S3, real-time monitoring of the rough cutting process of the mill arch contour, and correcting and finishing the cutting route of the high-pressure water jet, cutting off the margin reserved during rough cutting, and completing the fine processing of the mill arch contour; S4, inspecting the mill arch contour after fine processing, and completing the cutting when the inspection is qualified; when the inspection is unqualified, repeating step S3 until the inspection is qualified, and completing the production of the mill arch. The present invention cuts the mill arch out of the wide and thick continuous casting billets through a high-pressure water jet to realize the manufacture of the mill arch. Compared with cutting after mold casting, the production process is simple, the work efficiency is high, and batch production can be realized, reducing costs; by correcting and finishing the cutting route of the high-pressure water jet, the cutting route is optimized, and accurate cutting of complex frame structure castings is realized. By using high-pressure water jet cutting, deformation and cracks caused by heat effects can be effectively avoided, and higher cutting accuracy is achieved.

[0016] 2. The water jet cutting process for producing large frame castings based on wide and thick continuous casting billets provided by the present invention improves the smoothness of the billet surface by adopting pretreatment methods such as mechanical brushing, ultrasonic cleaning, grinding or polishing.

[0017] 3. The water jet cutting process for making large frame castings based on wide and thick continuous casting billets provided by the present invention uses two high-pressure water jets for alternating cutting during rough cutting, wherein the first high-pressure water jet is used for cutting and marking, and the second high-pressure water jet is used for complete cutting. The two-stage cutting ensures the accuracy of water jet cutting, while avoiding the phenomenon of incomplete cutting of wide and thick continuous casting billets in a single cutting.

[0018] 4. The water jet cutting process for making large frame castings based on wide and thick continuous casting billets provided by the present invention adopts pre-mixed abrasive water jet cutting for cutting, and the abrasive in the pre-mixed abrasive water jet cutting is aluminum oxide with a particle size range of 120 mesh-200 mesh; it can achieve fine cutting of wide and thick continuous casting billets, and can cut out frame structures of complex shapes to meet the needs of high-precision processing, and the pre-mixed abrasive water jet cutting has a high abrasive utilization rate and low equipment maintenance cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present invention will be further described in detail below with reference to the accompanying drawings.

[0020] Figure 1 It is a schematic diagram of the process flow of cutting of rolling mill arch. DETAILED DESCRIPTION

[0021] The principles and features of the present invention are described below in conjunction with the accompanying drawings. The examples are only used to explain the present invention and are not used to limit the scope of the present invention. If no specific conditions are specified in the embodiments, they are carried out according to conventional conditions or conditions recommended by the manufacturer.

[0022] Embodiment 1: A water jet cutting process for manufacturing large frame castings based on wide and thick continuous casting billets comprises the following steps: S1. Pretreatment of wide and thick continuous casting billets; S2. Use a high-pressure water jet to perform rough cutting of the mill arch profile on the pre-treated wide and thick continuous casting billet; S3, real-time monitoring of the rough cutting process of the mill arch profile, and correction and finishing of the cutting route of the high-pressure water jet, cutting off the margin reserved during the rough cutting, and completing the fine processing of the mill arch profile; S4, inspect the mill arch profile after fine machining, and when the inspection is qualified, complete the cutting; when the inspection is unqualified, repeat step S3 until the inspection is qualified and complete the cutting.

[0023] The present invention uses a high-pressure water jet to cut the wide and thick continuous casting billet into a rolling mill arch to realize the manufacture of the rolling mill arch. Compared with cutting after mold casting, the production process is simple and the work efficiency is high. It can realize mass production and reduce costs. By correcting and finishing the cutting route of the high-pressure water jet and optimizing the cutting route, accurate cutting of complex frame structure castings can be achieved. By using high-pressure water jet cutting, deformation and cracks caused by thermal effects can be effectively avoided, and high cutting accuracy is achieved.

[0024] Specific: Since high-pressure water jet cutting is a cold cutting process, no heat-affected zone is generated during the cutting process, avoiding material deformation and cracks that may be caused by traditional cutting processes. High-pressure water jet cutting can achieve higher cutting accuracy, especially suitable for processing complex frame structures and large castings. High-pressure water jet cutting has high accuracy, reducing the need for subsequent processing (such as grinding and polishing), thereby saving production costs and time. This process can be applied to castings of various materials and different sizes, especially in the processing of castings of large frame structures.

[0025] Embodiment 2: Based on Example 1, the pretreatment includes mechanical brushing, ultrasonic cleaning, grinding or polishing.

[0026] Specifically, the smoothness of the surface of the ingot is improved by pre-treatment methods such as mechanical brushing, ultrasonic cleaning, grinding or polishing. Before high-pressure water jet cutting, the surface of the wide and thick continuous casting ingot is first cleaned. Mechanical brushes, ultrasonic cleaning and other methods can be used to remove oxide layers, impurities and oil stains. If the surface of the ingot is relatively rough, it can be made smoother by grinding or polishing to improve the accuracy of water jet cutting. The wide and thick continuous casting ingot is 400mm thick, 3800mm long and 2500mm wide. The wide and thick continuous casting ingot of this size is used for cutting large frame structures. In actual operation, the wide and thick continuous casting ingot of a specific size can be selected according to needs to meet the cutting of large frame structures.

[0027] Embodiment 3: On the basis of Example 2, when the rough cutting of the mill arch profile is performed in step S2, holes are firstly processed on the four corners of the wide and thick continuous casting billet after pretreatment, and then the rough cutting is performed according to the three-dimensional model.

[0028] Specifically, the four corners of the continuous casting billet are firstly processed with holes, which not only avoids thermal deformation during material processing, but also ensures that the hole processing has a higher precision.

[0029] Preferably, during the rough cutting, a monitoring camera and an infrared sensor are used at the front end of the cutting area.

[0030] Specifically, by using a monitoring camera at the front end of the cutting area, when the monitoring camera at the front end of the cutting area detects that the wide and thick continuous casting billet has entered the mileage, the tool starts to move in parallel with the wide and thick continuous casting billet, and after the infrared sensor detects the front end of the wide and thick continuous casting billet, the water jet aligns with the preset starting point; this facilitates accurate monitoring of the arrival of the wide and thick continuous casting billet and improves cutting accuracy.

[0031] Embodiment 4: On the basis of Example 3, during the rough cutting, two high-pressure water jets are used for alternating cutting, wherein the first high-pressure water jet is used for cutting and marking, and the second high-pressure water jet is used for complete cutting.

[0032] Specifically, two high-pressure water jets are used to cut alternately, thereby reducing the wear of the cutting tool by the high-pressure water flow and ensuring the processing efficiency.

[0033] Preferably, when the first high-pressure water jet is used for cutting and marking, its preset water flow pressure only needs to achieve a cutting depth of more than half the thickness of the wide and thick continuous casting billet.

[0034] Specifically, the first high-pressure water jet performs cutting and marking, and its preset water flow pressure only needs to achieve a cutting depth of more than half of the casting thickness. After the first high-pressure water jet cuts 50-100cm, the second high-pressure water jet starts to move and completely cuts off the wide and thick continuous casting billet. The two-stage cutting ensures the accuracy of water jet cutting and avoids the phenomenon of incomplete cutting of wide and thick continuous casting billets in a single cut.

[0035] Preferably, the rough cutting comprises the following steps: first, rough cutting and marking of the outer contour of the rolling mill arch are performed, and then, rough cutting of the inner contour of the rolling mill arch is performed; finally, rough cutting of the contour of the rolling mill arch in the thickness direction is performed to complete the rough cutting of the contour of the rolling mill arch.

[0036] Specifically, after the rough cutting of the outer contour of the rolling mill arch is completed, the high-pressure water jet moves to the preset starting point of the inner contour processing, and starts the rough cutting of the inner contour of the rolling mill arch. Two high-pressure water jets are used to cut in sequence to cut off the excess part in the middle of the rolling mill arch and process the inner contour of the rolling mill arch. After the rough cutting of the inner contour of the rolling mill arch is completed, the high-pressure tool is moved to the third preset starting point, and the tool is adjusted to keep it horizontal, and the processing of the contour in the thickness direction of the rolling mill arch is started to cut out the approximate contour. After the approximate contour of the entire rolling mill arch is cut out, the robotic arm removes the excess of the continuous casting billet left by the above cutting process. The operation is simple.

[0037] Embodiment 5: Based on Example 4, the two high-pressure water jets are both provided with pressure sensors.

[0038] Specifically, a pressure sensor is installed on the high-pressure water jet to monitor the working pressure of the high-pressure water jet, and the water pressure regulator installed on the high-pressure water pump is controlled by the system (the system is an existing control system, and the control system is used to control the water pressure in the water pressure regulator installed on the high-pressure water pump, which is selected according to actual needs) to realize automatic control of the working pressure of the water jet, so that the water pressure is maintained within a certain range to ensure effective cutting of the high-pressure water jet.

[0039] Embodiment 6: Based on Example 5, the cutting adopts pre-mixed abrasive water jet cutting.

[0040] Specifically, the pre-mixed abrasive water jet cutting is adopted, which has high safety, good environmental protection, strong cutting ability and high working efficiency.

[0041] Preferably, the abrasive in the pre-mixed abrasive water jet cutting is aluminum oxide with a particle size range of 120 mesh to 200 mesh.

[0042] Specifically, the abrasive is made of aluminum oxide with a particle size range of 120 mesh to 200 mesh, which can achieve fine cutting of wide and thick continuous casting billets and can cut complex-shaped frame structures to meet the needs of high-precision processing. The pre-mixed abrasive cutting system has high abrasive utilization and low equipment maintenance costs.

[0043] Embodiment 7: On the basis of Example 6, the cutting route of the high-pressure water jet is corrected and refined by using control software, and the control software includes FlowNest, NEWCAM and ALMA (A-code) ACT / CUT.

[0044] Specifically, control software is used to optimize the cutting route of the high-pressure water jet to meet the cutting needs of complex frame structures and improve cutting efficiency and cutting accuracy.

[0045] Preferably, during cutting, the cutting of the high-pressure water jet is dynamically monitored by installing monitoring cameras equidistantly in the cutting work area.

[0046] Specifically, the detection of machining accuracy is improved by monitoring cameras.

[0047] Preferably, the monitoring camera is a laser scanning camera.

[0048] Specifically, finishing begins, using laser scanning to monitor the contour of the wide and thick continuous casting billet in real time, and transmits it to the control system to correct and refine the high-pressure water jet cutting route, gradually cutting in layers, and removing the margin reserved during rough processing. After the contour of the rolling mill arch scanned by the laser is qualified, the system controls the high-pressure tool to move to the preset end point at the end. After the sensor detects the high-pressure water jet, it means that the cutting process is completed; if the inspection fails, re-finishing is performed. The cut surface is checked by image recognition technology to ensure that there are no obvious cracks, burns or other surface defects. If problems are found, they can be corrected by further trimming or cleaning.

[0049] Embodiment 8: On the basis of Example 7, the cutting is performed using a cutting tool, the cutting tool is installed on the workbench base, a water tank is installed under the workbench base, and the workbench base is hollow. During cutting, water carries the chips into the water tank through the hollow workbench base.

[0050] Specifically, the structure is simple and convenient for removing chips.

[0051] Preferably, a magnetic coil is provided in the water tank.

[0052] Specifically, by setting a magnetic coil connected in the water tank, metal chips can be adsorbed after power is turned on, so as to avoid chip loss, facilitate chip recovery and save materials.

[0053] Preferably, the water outlet of the water tank is connected to a filter.

[0054] Specifically, a filter is installed at the water outlet to filter the abrasive in the water, thereby realizing the recycling of water and reducing the waste of water and abrasive.

[0055] Preferably, after the overall cutting of the mill arch contour is completed, a high-pressure water flow of about 50-100 MPa is used to flush the cut surface.

[0056] Specifically, after the overall cutting is completed, a high-pressure water flow of about 50-100MPa is used to flush the cut surface to remove metal particles, residual cutting fluid and impurities attached to the surface. This not only avoids damage to the processed product caused by the water flow pressure, but also has good economy and practicality.

[0057] Preferably, Figure 1 As shown, the cutting process of the rolling mill arch includes the following steps: S1.1. Rough cutting and marking of the outer contour of the rolling mill housing; S1.2, Rough cutting of the outer contour of the rolling mill arch; S1.3, Rough cutting and marking of the inner contour of the mill arch; S1.4, Rough cutting of inner contour of rolling mill arch; S1.5, Rough cutting and marking of the mill arch thickness direction contour; S1.6, Rough cutting of the mill arch thickness direction profile; S1.7, remove the remaining material after cutting; S1.8, laser scanning monitors the cutting process; S1.9, according to the scanning results and model, fine-tune and plan the cutting path; S1.10, precision cutting of outer contour of rolling mill arch; S1.11, precision cutting of inner contour of rolling mill arch; S1.12, precision cutting of the mill arch thickness direction profile; S1.13, laser scanning is used to check whether the mill arch profile after cutting is qualified. If qualified, the tool returns to the starting point; if unqualified, the above steps S1.8-S1.13 are repeated until the test result is qualified.

[0058] Specifically, the mill arch is made with high cutting accuracy, suitable for processing complex frame structures and large castings, reducing the need for subsequent processing (such as grinding and polishing), thereby saving production costs and time. It can be applied to castings of various materials and different sizes, especially in the processing of castings of large frame structures.

[0059] In the description of the present invention, it is necessary to understand that the orientation or positional relationship indicated by terms such as "lower" and "inner" are based on the orientation or positional relationship shown in the drawings, 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. Therefore, the terms describing the positional relationship in the drawings are only used for illustrative purposes and cannot be understood as a limitation on the present invention.

[0060] The above examples are merely illustrative of the present invention and do not constitute a limitation on the protection scope of the present invention. All designs that are the same or similar to the present invention fall within the protection scope of the present invention.

Claims

1. A water jet cutting process for producing large frame castings based on wide and thick continuous casting billets, characterized in that: The steps include: S1. Pretreatment of wide and thick continuous casting billets; S2. Use a high-pressure water jet to perform rough cutting of the mill arch profile on the pre-treated wide and thick continuous casting billet; S3, real-time monitoring of the rough cutting process of the mill arch profile, and correction and finishing of the cutting route of the high-pressure water jet, cutting off the margin reserved during the rough cutting, and completing the fine processing of the mill arch profile; S4, inspect the contour of the mill arch after fine processing, and when the inspection is qualified, complete the cutting; when the inspection is unqualified, repeat step S3 until the inspection is qualified, and complete the production of the mill arch.

2. The water jet cutting process for producing large frame castings based on wide and thick continuous casting billets according to claim 1, characterized in that: The pretreatment includes mechanical brushing, ultrasonic cleaning, grinding or polishing.

3. The water jet cutting process for producing large frame castings based on wide and thick continuous casting billets according to claim 1, characterized in that: When the rough cutting of the mill arch profile is performed in step S2, holes are firstly processed at the four corners of the pre-treated wide and thick continuous casting billet, and then the rough cutting is performed according to the three-dimensional model.

4. The water jet cutting process for producing large frame castings based on wide and thick continuous casting billets as claimed in claim 3, characterized in that: During the rough cutting, two high-pressure water jets are used for alternate cutting, wherein the first high-pressure water jet is used for cutting and marking, and the second high-pressure water jet is used for complete cutting.

5. The water jet cutting process for producing large frame castings based on wide and thick continuous casting billets as claimed in claim 4, characterized in that: When the first high-pressure water jet is used for cutting and marking, the preset water flow pressure only needs to achieve a cutting depth of more than half the thickness of the wide and thick continuous casting billet.

6. The water jet cutting process for producing large frame castings based on wide and thick continuous casting billets as claimed in claim 4, characterized in that: The two high-pressure water jets are both provided with pressure sensors.

7. The water jet cutting process for producing large frame castings based on wide and thick continuous casting billets according to claim 1, characterized in that: The cutting is performed by pre-mixed abrasive water jet cutting.

8. The water jet cutting process for producing large frame castings based on wide and thick continuous casting billets as claimed in claim 7, characterized in that: The abrasive in the pre-mixed abrasive water jet cutting is aluminum oxide with a particle size range of 120 meshes to 200 meshes.

9. The water jet cutting process for producing large frame castings based on wide and thick continuous casting billets according to claim 1, characterized in that: The cutting is performed by a cutting tool, which is installed on a workbench base. A water tank is installed below the workbench base, and the workbench base is hollowed out. During cutting, water carries the chips into the water tank through the hollowed-out workbench base.

10. The water jet cutting process for manufacturing large frame castings based on wide and thick continuous casting billets according to claim 9, characterized in that: A magnetic coil is arranged and connected in the water tank.

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