Axle housing resin sand casting process

Abstract

The invention relates to the technical field of axle housing casting processes, and discloses an axle housing resin sand casting process which comprises the following steps: S1, mixing mixed sand in proportion by adopting a fixed double-arm sand mixer to obtain mixed mixed sand; filling the mixed sand into a sand box, carrying out layered pounding, dismounting the mold, repairing the sand mold, cleaning the surface, uniformly brushing a special casting coating on the surface of the sand mold, and drying; s2, core sand is mixed according to the process proportion, the core sand is loaded into a core box, a sand core is pounded and solidified, the core box is disassembled, the complete sand core is taken out, the sand core is installed in a corresponding sand mold, accurate positioning is ensured, the upper mold and the lower mold are aligned and closed, a complete mold cavity is formed, and the assembled sand box is transferred to a casting station to be prepared for pouring; by designing a reasonable pouring system, qualified products are produced, the pouring temperature is controlled, the material ratio is adjusted, and the chemical components of the products are guaranteed.

Description

Technical Field

[0001] The present invention belongs to the technical field of axle housing casting processes, and specifically relates to a resin sand casting process for axle housings. Background Art

[0002] Due to the complex structure and uneven wall thickness of the axle housing, there are many deficiencies in the known casting methods. The gating system is unreasonable, and defects such as shrinkage porosity are likely to occur. When the pouring temperature is too high, sand adhesion is likely to occur, and when it is too low, cold shuts, incomplete pouring, etc. are likely to occur. If the chemical composition is unqualified, the casting will be scrapped. For this reason, a resin sand casting process for axle housings is proposed. Summary of the Invention

[0003] To solve the problems raised in the above background art, the present invention provides the following technical solutions:

[0004] A resin sand casting process for axle housings is provided, including the following steps:

[0005] S1. Use a fixed double-arm muller to mix the molding sand in proportion to obtain the well-mixed molding sand; fill the well-mixed molding sand into the sand box and ram it in layers, disassemble the mold, repair and clean the surface of the sand mold, evenly brush a special casting coating on the surface of the sand mold and dry it;

[0006] S2. Mix the core sand according to the process ratio, load the core sand into the core box and ram and cure the core, disassemble the core box, take out the complete core, install the core into the corresponding sand mold to ensure accurate positioning, align the upper and lower molds and close the box to form a complete cavity, and transfer the assembled sand box to the casting station for pouring preparation;

[0007] S3. Weigh the raw materials according to the process requirements and the material of the casting, add the ingredients to the melting furnace for heating and melting, pour out the melted metal liquid from the melting furnace, and promptly clean the floating slag to ensure that the temperature and chemical composition meet the casting requirements before transfer;

[0008] S4. Pour the metal liquid smoothly into the cavity according to the process requirements to ensure uniform pouring and avoid generating defects, and let it stand for the metal liquid to solidify;

[0009] S5. Remove the sand box to obtain the casting and clean the residual sand on the surface of the casting;

[0010] S6. Heat-treat the casting according to the material and performance requirements to improve the mechanical properties and release the internal stress;

[0011] S7. Shot blast the casting to further improve the surface finish and quality of the casting.

[0012] Further, the raw materials of the molding sand include silica sand, reclaimed sand, phenolic resin, and curing agent.

[0013] Further, the steps before installing the core into the corresponding mold in step S2 further include:

[0014] S21. Trim the surface of the core to remove burrs and excess sand;

[0015] S22. Uniformly brush the surface coating on the core to enhance the surface strength and high-temperature resistance;

[0016] S23. Dry the core coating to ensure its complete curing.

[0017] Further, the specific steps of the detection in step S3 during heating and melting include:

[0018] S31. Control the melting temperature and regularly take samples to detect the chemical composition;

[0019] S32. Add necessary refining agents for degassing and slag removal to improve the quality of the molten metal.

[0020] Further, the temperature measuring device is a thermocouple temperature gun.

[0021] Further, the steps before smoothly injecting the molten metal into the cavity in step S4 further include the steps:

[0022] S41. Inspect and trim the ladle, preheat it to the specified temperature, perform deoxidation treatment in the ladle, and clean the scum on the surface of the molten metal;

[0023] S42. Use the temperature measuring device to detect the temperature of the molten metal to ensure compliance with the casting process requirements.

[0024] Further, the specific steps of cleaning the residual sand on the surface of the casting in step S5 include:

[0025] S51. Use a shot blasting machine to clean the surface of the casting to remove the oxide scale and adhering mold sand;

[0026] S52. Cut the gating system and riser of the casting to separate the excess parts;

[0027] S53. Repair the defects on the surface of the casting, weld the pores or cracks, and grind it to be smooth.

[0028] Compared with the prior art, the beneficial effects of the present invention are:

[0029] By designing a reasonable gating system, ensuring the production of qualified products, controlling the pouring temperature, and adjusting the material ratio, the chemical composition of the products is guaranteed. Description of the Drawings

[0030] The accompanying drawings are used to provide a further understanding of the present invention and form a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation to the present invention. In the accompanying drawings:

[0031] Figure 1 It is a flowchart of a resin sand casting process for a axle housing provided by an embodiment of the present invention; Specific embodiments

[0032] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments; based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the scope of protection of the present invention.

[0033] It is provided by Figure 1 An embodiment of the present invention provides a resin sand casting process for an axle housing, including the following steps:

[0034] S1. Use a fixed double-arm sand mixer to mix the molding sand in proportion to obtain the well-mixed molding sand; fill the well-mixed molding sand into the sand box and ram it layer by layer, disassemble the mold, repair and clean the surface of the sand mold, evenly brush a special casting coating on the surface of the sand mold and dry it;

[0035] S2. Mix the core sand according to the process ratio, load the core sand into the core box and ram and cure the sand core, disassemble the core box, take out the complete sand core, install the sand core into the corresponding sand mold to ensure accurate positioning, align the upper and lower molds and close the box to form a complete cavity, and transfer the assembled sand box to the casting station for pouring preparation;

[0036] S3. Weigh the raw materials according to the process requirements and the material of the casting, add the ingredients to the melting furnace for heating and melting, pour out the melted metal liquid from the melting furnace, and promptly clean the floating slag to ensure that the temperature and chemical composition meet the casting requirements before transfer;

[0037] In this embodiment, the raw material ratio is C = 0.18%, Si = 0.5%, Mn = 1.1%, P ≤ 0.03%, S ≤ 0.03%, and the balance is Fe;

[0038] S4. Pour the metal liquid into the cavity smoothly according to the process requirements to ensure uniform pouring and avoid defects, and let it stand for the metal liquid to solidify;

[0039] S5. Remove the sand box to obtain the casting and clean the residual sand on the surface of the casting.

[0040] S6. Heat-treat the casting according to the material and performance requirements to improve the mechanical properties and release the internal stress;

[0041] S7. Shot blast the casting to further improve the surface finish and quality of the casting.

[0042] In this embodiment, the raw materials of the mixed molding sand include green sand, reclaimed sand, phenolic resin and curing agent.

[0043] Among them, the steps before installing the sand core into the corresponding sand mold in step S2 further include:

[0044] S21. Trim the surface of the sand core to remove burrs and excess sand.

[0045] S22. Uniformly brush the surface coating of the sand core to enhance the surface strength and high-temperature resistance.

[0046] S23. Dry the sand core coating to ensure its complete curing.

[0047] In another embodiment, the specific steps of the detection in step S3 during heating and melting include:

[0048] S31. Control the melting temperature and regularly take samples to detect the chemical composition.

[0049] S32. Add necessary refining agents for degassing and slag removal to improve the quality of the molten metal.

[0050] The temperature measuring device is a thermocouple temperature gun.

[0051] The steps before the smooth injection of the molten metal into the cavity in step S4 further include steps:

[0052] S41. Inspect and trim the ladle, preheat it to the specified temperature, perform deoxidation treatment in the ladle, and clean the dross on the surface of the molten metal.

[0053] S42. Use a temperature measuring device to detect the temperature of the molten metal to ensure that it meets the requirements of the casting process.

[0054] The steps of cleaning the residual sand on the surface of the casting in step S5 specifically include:

[0055] S51. Use a shot blasting machine to clean the surface of the casting to remove the scale and adhering molding sand.

[0056] S52. Cut the gating system and riser of the casting to separate the excess part.

[0057] S53. Repair the defects on the surface of the casting, weld the pores or cracks, and grind it to be smooth.

[0058] It should be noted that in this text, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, such that a process, method, article or device comprising a series of elements not only includes those elements but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device.

[0059] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A bridge shell resin sand casting process, characterized in that: The following steps are involved: S1. Use a fixed double-arm sand mixer to mix the mixed sand according to proportion to obtain mixed sand, fill the mixed sand into a sand box and pound it layer by layer, disassemble the mold, repair the sand mold, clean the surface, evenly apply special casting paint on the surface of the sand mold and dry it; S2. Mix the core sand according to the process ratio, put the core sand into the core box and pound the solidified sand core, disassemble the core box, take out the complete sand core, install the sand core into the corresponding sand mold, ensure accurate positioning, align the upper and lower molds with the combined box to form a complete mold cavity, and transport the assembled sand box to the casting station for pouring; S3. According to the process requirements and casting material, weigh the raw materials according to the proportion, add the ingredients into the smelting furnace for heating and melting, take the smelted metal liquid out of the smelting furnace, and clean the slag in time to ensure that the temperature and chemical composition meet the casting requirements before transportation; S4. Inject the molten metal into the mold cavity smoothly according to the process requirements to ensure uniform pouring and avoid defects, and let the molten metal solidify; S5, dismantle the sand box, obtain the casting and clean the residual sand on the surface of the casting; S6. Heat treat the castings according to the material and performance requirements to improve the mechanical properties and release the internal stress; S7. Shot blast the casting to further improve the surface finish and quality of the casting.

2. The method according to claim 1, characterized in that: The raw materials of the mixed sand include original sand, regenerated sand, phenolic resin and curing agent.

3. The method according to claim 1, characterized in that: The step S2 before installing the sand core into the corresponding sand mold also includes: S21, trim the surface of the sand core to remove burrs and excess sand; S22, evenly apply the coating on the surface of the sand core to enhance the surface strength and high temperature resistance; S23, dry the sand core coating to ensure that it is completely cured.

4. The method according to claim 1, characterized in that: The specific steps of performing detection during heating and melting in step S3 include: S31, control the melting temperature, and take samples regularly to detect the chemical composition; S32. Add necessary refining agents to carry out degassing and slag removal to improve the quality of molten metal.

5. The method according to claim 1, characterized in that: The temperature measuring device is a thermocouple temperature measuring gun.

6. The method according to claim 1, characterized in that The step S4 further comprises the following steps before the molten metal is smoothly injected into the mold cavity: S41, inspect and trim the ladle, preheat it to the specified temperature, perform deoxidation treatment in the ladle, and clean the slag on the surface of the molten metal; S42. Use temperature measuring equipment to detect the temperature of the molten metal to ensure that it meets the casting process requirements.

7. The method according to claim 1, characterized in that The step S5 of cleaning the residual sand material on the surface of the casting specifically includes: S51. Use a shot blasting machine to clean the surface of the casting to remove the oxide scale and attached molding sand; S52, cutting the pouring system and riser of the casting and separating the excess parts; S53. Repair defects on the casting surface, weld pores or cracks, and grind to smoothness.

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