Manufacturing method of filler conforming to design density

Abstract

The invention relates to a manufacturing method of a filler meeting design density, the density of a filler material needing design density is 1.82 g / cm < 3 >, cement, sand, wood chips and water are mixed according to the mass percent, the actual density of the mixture can reach the design density, and the optimal proportion of the cement, the sand, the tap water and the wood chips is 27.62%, 68.52%, 2.76% and 1.1%; after a mixture of substitutes is prepared according to the proportion, filling is conducted according to the volume of an inner cavity of a product, curing is conducted for 24 hours after filling is completed, the product is weighed, the gravity center is measured, the total mass and the gravity center meet the design requirements, the overall state meets the test conditions, and through test verification, the manufacturing method of the novel filler meeting the design density is reasonable and effective.

Description

Technical Field

[0001] This invention belongs to the technical field of product cavity filling materials, and particularly relates to a method for manufacturing a filler with a design density. Background Technology

[0002] During the development of some products, the prototype design typically undergoes various tests. To ensure complete consistency with the final product, the internal cavities of the product during the development phase are often filled with materials of the designed density. However, in some special testing projects, to monitor product deformation and reduce testing costs, materials with a density close to the design density are used for filling.

[0003] The filler is generally a solid column made of nylon material with a density close to that of the design, according to the internal dimensions of the product. After assembly, the product has the same total mass and center of gravity as in the real state during the test.

[0004] Currently, in the development projects of various product models, multiple batches of products filled with solid columnar materials are frequently manufactured. However, during production, it was found that the density of each batch of nylon blanks purchased fluctuated significantly. This resulted in large deviations in the overall weight of the finished product after production and assembly according to the drawings, affecting the final testing. Frequent changes to the drawings to match the weight did not meet the requirements of the product model. An inspection of the production of each batch of nylon blanks exhibiting density fluctuations revealed that the cause was the inconsistent quality of the raw materials used to manufacture each batch of blanks. Considering production costs, precise control of the filler density could not be guaranteed. Summary of the Invention

[0005] The purpose of this invention is to overcome the fluctuations in the density of existing materials and assembly defects, and to provide a method for manufacturing fillers that meet the design density using cement, sand and wood chips as raw materials, so that the actual density of the filler meets the design requirements, and the weight and center of gravity of the final product are within the acceptable range.

[0006] The objective of this invention is achieved as follows: a method for preparing a filler with a designed density, characterized by using suitable cement, sand, sawdust, and water, optimizing the mass percentages and operational steps, to mix them to a density of 1.82 g / cm³. 3 The filling material is filled into the product cavity and cured for 24 hours. The final product's weight and center of gravity must be within acceptable limits. The requirements for each component are shown in the table below: name Require cement Silicate cement, grade PO42.5, sand <![CDATA[The average particle size is ≥ 0.35 mm, SiO2 ≥ 65% by weight percentage, the mud content ≤ 5%, and no large mud lumps or pebbles are allowed.]]> Wood chips Particle size 0.5-1.5mm, moisture content <5% by weight. water purified water The percentage of mass is shown in the table below: Components cement% sand% water% Wood chips Quality percentage 27.62 68.52 2.76 1.1 The specific operating steps are as follows: Step 1) Raw material inspection: Check whether the parameters of each component are qualified according to the requirements. Step 2) Prepare a small batch of 5 kg of filling material according to the mass percentage, and check the weight using a calibration mold; The density of the composite core is 1.82 g / cm³. 3 Fluctuation <0.02g / cm 3 ; Step 3) After verifying that the density is qualified, prepare the filling material according to the product requirements, fill it into the inner cavity of the product, and cure it for 24 hours after filling. Step 4) Weigh the product and measure its center of gravity. The total mass and center of gravity meet the design requirements, and the overall condition is ready for testing.

[0007] In the above steps, the filling is carried out segment by segment according to the filling method. The filling weight is recorded, and each segment is compacted using a self-made pressure bar tool after filling. The distance from the end face of each filling segment to the tail end of the shell is measured with a ruler. If the distance meets the requirements of the scheme, the next segment is filled. After filling, the product is cured for 24 hours. The total weight of the product is weighed, the center of gravity is measured, and the test results are confirmed to meet the filling scheme. After experimental verification, this new filling material manufacturing method that meets the design density is reasonable and effective.

[0008] The present invention will achieve the following effects by adopting the above technical solution: The components are mixed, filled, and cured according to the mass percentage and operating procedures. The actual density of the final filling meets the user's design requirements, avoiding the quality deviation of the filler caused by nylon materials. Detailed Implementation

[0009] Example 1: Prepare a platform scale and a calibration mold (10cm×10cm×10cm inner cavity) in advance, turn on the scale for calibration, weigh the calibration mold to remove the tare.

[0010] Step 1) Check the state of cement, sand, and sawdust according to the requirements of each component, and test the moisture content; the cement is silicate cement, grade PO42.5; the sand has an average particle size ≥0.35mm, SiO2 ≥65% by weight, mud content ≤5%, and large mud lumps and pebbles are not allowed; the sawdust has a particle size of 0.5-1.5mm, moisture content <5% by weight, and the water is pure water; Step 2) Prepare a small batch of 5 kg of filling material according to the mass percentage, and check the weight using a calibration mold; The density of the composite core is 1.82 g / cm³. 3 Fluctuation <0.02g / cm 3 ; Step 3) Prepare all materials according to the mass percentage and mix them evenly; fill the weighing mold, weigh it, and verify that the weight is 1820g. If there is a deviation, adjust the density by adding river sand or sawdust until the final density reaches 1.82g / cm³. 3Re-stir the material thoroughly; fill it section by section according to the filling method, and record the filling weight. After each section is filled, use a self-made pressure bar tool to compact it; use a ruler to measure the distance between the end face of each filling material and the plane of the tail end of the shell. If the distance meets the requirements of the plan, then proceed to the next section; allow 24 hours for curing after filling. Step 4) Weigh the product and measure its center of gravity. The total mass and center of gravity meet the design requirements, and the overall condition meets the test conditions. Confirm that the test results meet the filling plan.

Claims

1. A method for manufacturing a filler with a designed density, characterized in that, Using qualified cement, sand, sawdust, and water, and optimizing the mass percentages and operating procedures, a mixture with a density of 1.82 g / cm³ was prepared. 3 The filling material is filled into the product cavity and cured for 24 hours. The final product's weight and center of gravity must be within acceptable limits. The requirements for each component are shown in the table below: The percentage of mass is shown in the table below: The specific steps are as follows: Step 1) Raw material inspection: Check whether the parameters of each component are qualified according to the requirements. Step 2) Prepare a small batch of 5 kg of filling material according to the mass percentage, and check the weight using a calibration mold; The density of the composite core is 1.82 g / cm³. 3 Fluctuation <0.02g / cm 3 ; Step 3) After verifying that the density is qualified, prepare the filling material according to the product requirements, fill it into the inner cavity of the product, and cure it for 24 hours after filling. Step 4) Weigh the product and measure its center of gravity. The total mass and center of gravity meet the design requirements, and the overall condition is ready for testing.

2. The method for manufacturing a novel filler conforming to a designed density according to claim 1, characterized in that, In the above steps, fill the material section by section according to the filling method. Record the filling weight. After each section is filled, use a self-made pressure bar tool to compact it. Use a ruler to measure the distance between the end face of each filling material and the plane of the tail end of the shell. If the distance meets the requirements of the plan, then fill the next section. After filling, cure for 24 hours, weigh the total weight of the product, measure the center of gravity, and confirm that the test results meet the filling plan.