Novel composite water jacket and casting method thereof

Abstract

The invention belongs to the technical field of water jacket casting, and discloses a novel composite water jacket and a casting method thereof.The novel composite water jacket comprises a heat conduction copper plate, a heat exchange pipe penetrates through the heat conduction copper plate, the novel composite water jacket is characterized in that the heat conduction copper plate is of a fan-shaped structure, and a second fan-shaped face on one side of the heat conduction copper plate is provided with a grid plate used for installing abrasion-resistant ramming materials. The invention further discloses a novel composite water jacket casting method which comprises the following steps: manufacturing the cavity, and sequentially completing the steps of forming and fixing the wear-resistant grid steel belt, welding the anchor flukes, pretreating and fixing the red copper pipe, preheating the cavity, relieving stress, performing gravity casting, performing subsequent processing and the like. The problem that a traditional water jacket is insufficient in wear resistance is solved, the service life of the water jacket is prolonged, and the water jacket is suitable for batch production.

Description

Technical Field

[0001] This invention belongs to the field of water jacket casting technology, and specifically relates to a novel composite water jacket and its casting method. Background Technology

[0002] Traditional water jackets are mostly cast from a single copper material, which has problems such as insufficient wear resistance at high temperatures and easy cracking due to thermal stress. This results in a short service life in heavy-duty equipment such as industrial furnaces, and the cooling channels are prone to blockage or corrosion, affecting the operating efficiency and safety of the equipment.

[0003] In the existing casting process of composite water jackets, the wear-resistant layer is not firmly bonded to the matrix and has poor thermal shrinkage matching, which easily leads to delamination and peeling, making it difficult to meet the stringent reliability requirements of high-end equipment. Summary of the Invention

[0004] One object of the present invention is to provide a novel composite water jacket, comprising a heat-conducting copper plate through which heat exchange tubes pass. The heat-conducting copper plate has a fan-shaped structure and is provided with a first fan surface and a second fan surface parallel to each other. The second fan surface is provided with a grid plate for installing wear-resistant ramming material.

[0005] Furthermore, the heat-conducting copper plate has symmetrical transition bosses on both sides of the first fan-shaped surface. The transition bosses are bent plate-shaped structures. One side of the transition boss is perpendicularly connected to the first fan-shaped surface, and the other side is parallel to the first fan-shaped surface. The heat exchange tube located in the heat-conducting copper plate is parallel to the first fan-shaped surface and extends along the arc-shaped side of the first fan-shaped surface. The end of the heat exchange tube passes through the transition boss and extends to the outside of the transition boss.

[0006] Furthermore, the mesh plate is a mesh structure formed by connecting and enclosing wear-resistant alloy steel strips.

[0007] Furthermore, the heat exchange tube is a copper tube.

[0008] Furthermore, the first sector has a heat exchange tube outline structure that protrudes from the first sector.

[0009] Furthermore, the first fan surface is integrally formed with a mounting part, which protrudes from the first fan surface and has mounting holes.

[0010] Furthermore, the first and second fan surfaces on both sides of the heat-conducting copper plate are respectively provided with hanging rings.

[0011] Another object of the present invention is to provide a novel composite water jacket casting method for casting the above-mentioned novel composite water jacket, comprising the following steps: S1. Based on the design dimensions of the composite water jacket, calculate the thermal shrinkage rates between the wear-resistant mesh steel strips and between the wear-resistant mesh steel strips and copper, determine the machining allowance, and fabricate the wooden model cavity. S2. The high-strength wear-resistant alloy steel strip is made into a grid structure that fits the cavity; S3. Insert the formed wear-resistant mesh steel strip into the preset position in the sand box cavity and fix it; S4. On the surface of the wear-resistant mesh steel strip facing the inside of the cavity, weld L-shaped anchor claws (material consistent with the steel strip, specifications 15×10×3mm), with an anchor claw spacing of 80-120mm, distributed in a plum blossom pattern, to enhance the mechanical bonding force between the steel strip and the water jacket substrate.

[0012] S5. Cut the copper tubes according to the cooling channel path, fill them with fluid particles, and seal both ends of the copper tubes with heat-resistant alloy wire to prevent molten metal from seeping in during casting; lower the copper tubes into the corresponding positions in the cavity and fix them with refractory clay supports. S6. Send the sand box containing the embedded parts into the resistance furnace, heat it to 350-450℃, and keep it at that temperature for 2-3 hours to achieve hot mold casting pretreatment and eliminate the internal stress generated by the wear-resistant mesh steel strip during processing. S7. Molten copper is poured into the mold cavity using gravity casting, with the casting speed controlled at 5-8 kg / s to avoid erosion of the embedded parts. After casting, the mold is allowed to cool naturally to room temperature. The sand mold is removed and the riser is cleaned to obtain a new type of composite water jacket blank. S8. The blank is turned and ground to clear the flow particles inside the copper tube and form a smooth cooling channel.

[0013] Furthermore, in S1, the shrinkage rate of copper is 1.05%-1.08%, the length of each steel strip is 500mm, and the distance between the ends of the steel strip = the length of the steel strip * the shrinkage rate of copper.

[0014] Furthermore, in S5, the spacing between the copper tubes is ≥25mm, and the interval between the copper tubes and the mesh steel strip is 10-15mm.

[0015] The present invention has the following beneficial effects.

[0016] 1. The novel composite water jacket of this invention employs a fan-shaped heat-conducting copper plate paired with a mesh plate. The mesh plate is specifically made of wear-resistant alloy steel strip, providing a stable mounting carrier for the wear-resistant ramming material and effectively preventing material from falling off. The heat exchange tubes are made of copper and are arranged parallel to the arc-shaped side. The raised outline on the first fan surface visually shows the direction of the heat exchange tubes, and the spacing between the tubes and the distance from the mesh steel strip are reasonably controlled to ensure uniform cooling.

[0017] 2. The novel composite water jacket casting method of the present invention calculates the spacing between the ends of the steel strips in segments by using the thermal shrinkage rate of copper, and combines it with hot mold casting pretreatment at 350-450℃ to effectively eliminate the internal stress of steel strip processing, so that the steel strips fit tightly after the copper cools and shrinks. This solves the problem of thermal expansion mismatch between different materials and reduces cracks and delamination defects.

[0018] The pretreatment process, which involves filling copper tubes with fluid particles and fixing them with refractory clay supports, combined with precise pouring speed control of 5-8 kg / s, avoids erosion of embedded parts by molten metal and ensures that the cooling channels are well-formed and have good unobstructed flow after subsequent processing. The overall process is simple and controllable, with standardized operating conditions at each stage from cavity fabrication to blank processing, making it suitable for mass production. Attached Figure Description

[0019] Figure 1 This is a three-dimensional structural diagram of the novel composite water jacket in this invention.

[0020] Figure 2 This is a schematic diagram of one side of the mesh plate structure of the novel composite water jacket in this invention.

[0021] Figure 3 This is a schematic diagram of the structure of the novel composite water jacket with lifting rings on both sides in this invention.

[0022] In the figure: 1. Thermally conductive copper plate; 2. Heat exchange tube; 3. Mesh plate; 4. Transition boss; 5. Mounting part; 6. Raised profile; 7. Lifting ring; 8. First sector; 9. First end face; 10. Second end face; 11. Arc-shaped surface; 12. Second sector. Detailed Implementation

[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0024] This invention discloses a novel composite water jacket, in which the heat-conducting copper plate 1 has an overall fan-shaped structure, having two parallel first fan surfaces 8 and second fan surfaces 12, with an arc-shaped surface 11 perpendicularly connected between the two fan surfaces. The arc-shaped surface 11 has a first end surface 9 and a second end surface 10 at its two ends extending along the arc, and the first end surface 9 and the second end surface 10 are symmetrically arranged along the centerline of the arc-shaped surface 11.

[0025] The first sector 8 of the heat-conducting copper plate 1 is integrally formed with a mounting part 5. The outer surface of the mounting part 5 protrudes from the plane of the first sector 8, and the protrusion height is controlled within 10-15mm. Four evenly distributed mounting holes are provided on the mounting part 5.

[0026] The second sector 12 of the thermally conductive copper plate 1 is provided with a grid plate 3, the shape and size of which are adapted to the second sector 12. The grid plate 3 is composed of high-strength wear-resistant alloy steel strips connected together, the steel strips being 5mm thick. The grid steel strips provide an installation carrier for the wear-resistant ramming material, preventing the ramming material from falling off.

[0027] The thickness of the thermally conductive copper plate is 110mm, the width of the steel strip is 60mm, and the depth of the steel strip embedded in the thermally conductive copper plate is 10mm.

[0028] A heat exchange tube 2 is inserted inside the heat-conducting copper plate 1. The heat exchange tube 2 is parallel to the first sector 8 and extends from the first end face 9 to the second end face 10. In this embodiment, three heat exchange tubes 2 are arranged at even intervals to ensure uniform cooling. The heat exchange tubes 2 are made of copper. The heat-conducting copper plate 1 is specifically made of copper.

[0029] Transition bosses 4 are respectively provided on the first sector 8 near the first end face 9 and the second end face 10. The transition bosses 4 are L-shaped plate structures. One side of the transition bosses 4 is perpendicular to the first sector 8, and the other side is parallel to the first sector 8. The transition point is rounded to avoid stress concentration. The end of the heat exchange tube 2 passes through the transition bosses 4 along the heat-conducting copper plate 1, extends along the shape of the transition bosses 4, and protrudes from the end face of the transition bosses 4. The protruding part of the tube body is parallel to the first sector 8 to facilitate connection with external cooling pipes.

[0030] A raised profile 6 protruding from the surface is formed on the first sector 8. The raised profile 6 extends continuously along the arrangement path of the heat exchange tube 2, and its shape corresponds to the orientation profile of the heat exchange tube 2 within the heat-conducting copper plate 1. The protrusion height of the raised profile 6 is 5-8mm, which can visually show the orientation trajectory of the heat exchange tube 2.

[0031] The first sector 8 and the second sector 12 of the heat-conducting copper plate 1 are respectively equipped with lifting rings 7, which are made of forged round steel. The lifting rings 7 have a load-bearing capacity of not less than 500 kg, which facilitates the casting, lifting, transportation and on-site installation of the composite water jacket and avoids damage to the main structure during the lifting process.

[0032] This invention discloses a novel composite water jacket casting method for casting the aforementioned novel composite water jacket, specifically including the following steps: S1. Making the wooden model cavity: Calculate the spacing of the wear-resistant steel strip and the thermal shrinkage rate of copper according to the design dimensions of the composite water jacket.

[0033] The shrinkage rate of copper is 1.05%-1.08%; the spacing between the ends of the steel strip is calculated in segments, with each segment being 500mm long, and the spacing between the ends of adjacent steel strips in the length direction = steel strip length * copper shrinkage rate.

[0034] S2. Manufacturing wear-resistant mesh steel strip: Select a 5mm thick high-strength wear-resistant alloy steel strip, and form it into a mesh shape through stamping and bending, so that the overall size of the mesh matches the cavity. The mesh nodes are reinforced by welding to avoid deformation after forming.

[0035] S3. Fixing the pre-embedded wear-resistant mesh steel strip: Insert the formed wear-resistant mesh steel strip into the preset position in the sand box cavity, and fix it evenly with steel nails of 4-6mm diameter at a spacing of 100-150mm. The steel nails should penetrate into the sand mold to a depth of not less than 20mm to ensure that the steel strip does not shift during pouring.

[0036] S4. Welding anchor claws: On the surface of the wear-resistant mesh steel strip facing the inside of the cavity, weld L-shaped anchor claws (material is the same as the steel strip, specifications are 15×10×3mm), with the anchor claws spaced 80-120mm apart and distributed in a quincunx pattern to enhance the mechanical bonding force between the steel strip and the water jacket substrate.

[0037] S5. Pretreatment and Fixing of Copper Tubes: Select copper tubes with a wall thickness of 2-4mm, cut them according to the cooling channel path, and fill the inside with fluid particles with a particle size of 0.1-0.3mm. The fluid particles can be quartz sand. The two ends are sealed with heat-resistant alloy wire to prevent molten metal from seeping in during casting. The heat-resistant alloy wire can be nickel-chromium alloy wire. Place the copper tubes into the corresponding positions in the cavity and fix them with refractory clay supports to ensure that the tube spacing is ≥25mm and that there is a distance of 10-15mm between the tubes and the steel strip.

[0038] S6. Cavity preheating and stress relief: The sand box containing the embedded parts is sent into the resistance furnace and heated to 350-450℃. It is kept at this temperature for 2-3 hours to achieve hot mold casting pretreatment and at the same time eliminate the internal stress generated by the wear-resistant mesh steel strip during processing.

[0039] S7. Casting and Molding: Molten copper is injected into the mold cavity by gravity casting. The casting speed is controlled at 5-8 kg / s to avoid erosion of the embedded parts. After casting, the mold is naturally cooled to room temperature, the sand mold is removed, and the gating and riser are cleaned to obtain the new composite water jacket blank.

[0040] S8. Subsequent processing: The blank is turned and ground to ensure the dimensional accuracy and surface roughness (Ra≤3.2μm) of the water jacket, clear the flow particles in the copper tube, and form a smooth cooling channel.

[0041] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A novel composite water jacket, comprising a heat-conducting copper plate through which heat exchange tubes pass, characterized in that, The heat-conducting copper plate has a fan-shaped structure, with a first fan-shaped surface and a second fan-shaped surface parallel to each other. The second fan-shaped surface has a grid plate for installing wear-resistant ramming material.

2. The novel composite water jacket as described in claim 1, characterized in that, The heat-conducting copper plate has symmetrical transition bosses on both sides of the first fan-shaped surface. The transition bosses are bent plate-shaped structures. One side of the transition boss is perpendicularly connected to the first fan-shaped surface, and the other side is parallel to the first fan-shaped surface. The heat exchange tube located in the heat-conducting copper plate is parallel to the first fan-shaped surface and extends along the arc-shaped side of the first fan-shaped surface. The end of the heat exchange tube passes through the transition boss and extends to the outside of the transition boss.

3. The novel composite water jacket as described in claim 1 or 2, characterized in that, The mesh plate is a mesh structure formed by connecting and enclosing wear-resistant alloy steel strips.

4. The novel composite water jacket as described in claim 3, characterized in that, The heat exchange tube is made of copper.

5. The novel composite water jacket as described in claim 3, characterized in that, The first sector has a heat exchange tube outline structure that protrudes from the first sector.

6. The novel composite water jacket as described in claim 3, characterized in that, The first fan surface is integrally formed with a mounting part, which protrudes from the first fan surface and has mounting holes.

7. The novel composite water jacket as described in claim 3, characterized in that, The first and second fan-shaped surfaces on both sides of the heat-conducting copper plate are respectively equipped with hanging rings.

8. A novel composite water jacket casting method for preparing the novel composite water jacket as described in any one of claims 4-7, characterized in that, Includes the following steps: S1. Based on the design dimensions of the composite water jacket, calculate the thermal shrinkage rate of the wear-resistant mesh steel strip and copper, determine the machining allowance of the steel strip, and make the wooden model cavity; S2. The high-strength wear-resistant alloy steel strip is made into a grid structure that fits the cavity; S3. Insert the formed wear-resistant mesh steel strip into the preset position in the sand box cavity and fix it; S4. Weld L-shaped anchor claws onto the surface of the wear-resistant mesh steel strip facing the inside of the cavity; S5. Cut the copper tubes according to the cooling channel path, fill them with fluid particles, and seal both ends of the copper tubes with heat-resistant alloy wire to prevent molten metal from seeping in during casting. Place the copper tubes into the corresponding positions in the cavity and fix them with refractory clay supports. S6. Send the sand box containing the embedded parts into the resistance furnace, heat it to 350-450℃, and keep it at that temperature for 2-3 hours to achieve hot mold casting pretreatment and eliminate the internal stress generated by the wear-resistant mesh steel strip during processing. S7. Use gravity casting to inject molten copper into the mold cavity, and control the casting speed at 5-8 kg / s to avoid erosion of the embedded parts; After pouring, the material is allowed to cool naturally to room temperature. The sand mold is then removed and the risers are cleaned to obtain a new type of composite water jacket blank. S8. The blank is turned and ground to clear the flow particles inside the copper tube and form a smooth cooling channel.

9. The novel composite water jacket casting method as described in claim 8, characterized in that, In S1, the shrinkage rate of copper is 1.05%-1.08%, the length of each steel strip is 500mm, and the distance between the ends of the steel strip = the length of the steel strip * the shrinkage rate of copper.

10. The novel composite water jacket casting method as described in claim 8, characterized in that, In S5, the spacing between the copper tubes is ≥25mm, and the interval between the copper tubes and the mesh steel strip is 10-15mm.

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