A casting process for valve production

Abstract

The application relates to a casting process for valve production, characterized by comprising the following steps: preparing a blank; putting the clean blank into a smelting furnace, heating the blank until it becomes a molten state, the heating time is 20-50 min, the heating temperature is 1200-1450 DEG C, and the casting mold is heated at the same time, the casting mold has an electric heating wire in the inside, the electric heating wire is used for heating the casting mold, the heating temperature is 100-200 DEG C, so that the mold is in a preheating state; adding a release agent in the mold, then increasing the heating temperature of the mold, then pouring the molten metal solution in the molten state in the step two into the casting mold; testing the casting mold through a casting press, the time is 4-6 min, then cooling the mold, finally demolding, and thus obtaining a valve casting part; and performing shot blasting and polishing treatment on the valve casting part obtained in the step four.

Description

Technical Field

[0001] This invention relates to the field of valve manufacturing technology, specifically a casting process for valve manufacturing. Background Technology

[0002] Valves are common flow-stopping devices used in daily life and industrial production. They are used to regulate or cut off the flow of various media in pipelines such as coal gas, natural gas, water supply and drainage, and liquefied petroleum gas to prevent leakage. Therefore, pressure testing is usually required to ensure the tightness of the internal structure. The valve body is a pressure vessel, classified into high-pressure, medium-pressure, and low-pressure types according to the pressure it withstands. Valves are also widely used in medium-concentration acid or alkali liquid media in industries such as petroleum, chemical, food, and fiber, with operating temperatures below 600℃. Casting is a crucial step in valve production, generating waste gas. If this waste gas is not promptly removed, it will pollute the workshop environment; if directly discharged, it will pollute the outdoor environment. Furthermore, traditional casting processes are mostly manual, making the entire process time-consuming and labor-intensive. With continuous social development, automated equipment has been developed to replace manual labor. However, some precision equipment is very expensive, making it difficult to meet the needs of the general public. This invention proposes a new solution to these problems. Summary of the Invention

[0003] (a) Technical problems to be solved

[0004] To address the shortcomings of existing technologies, this invention provides a casting process for valve production, thereby resolving the problems mentioned in the background art.

[0005] (II) Technical Solution

[0006] To achieve the above objectives, the present invention provides the following technical solution: a casting process for valve production, comprising the following steps:

[0007] Step 1: Prepare the billet by cleaning and drying it to obtain a clean billet. Then, weigh the billet to obtain its weight before melting. Finally, place the billet on a heating platform for preheating.

[0008] Step 2: Place the clean billet obtained in Step 1 into the melting furnace and heat the billet until it becomes molten. The heating time is 20-50 minutes and the heating temperature is 1200-1450 degrees Celsius. At the same time, heat the casting mold. The casting mold has an electric heating wire inside. The electric heating wire heats the casting mold to a temperature of 100-200 degrees Celsius, so that the mold is in a preheated state.

[0009] Step 3: Add a release agent to the mold, then heat the mold to 950-1150 degrees Celsius for 10-15 minutes. Then pour the molten metal solution from Step 2 into the casting mold and let it stand for 10-15 minutes.

[0010] Step 4: Test press the casting mold using a casting press for 4-6 minutes, then cool the mold down, and finally demold to obtain the valve casting.

[0011] Step 5: The valve castings obtained in Step 4 are shot blasted and polished for 10-20 minutes to obtain the finished product.

[0012] Step Six: Inspect the finished product obtained in Step Five to check its surface smoothness and compressive strength.

[0013] In a further preferred embodiment, the preheating time in step one is 1-2 hours, and the preheating temperature is 50-80 degrees Celsius.

[0014] In a further preferred embodiment, the billet is cleaned and dried using a high-pressure water gun and a hot air dryer in step one, thereby obtaining a clean billet.

[0015] In a further preferred embodiment, after the finished product in step six passes the inspection, it is packaged, and the production date and batch number are printed on the packaging box so that customers can clearly know the relevant information of the finished product.

[0016] In a further preferred embodiment, step four involves shot blasting the valve castings to remove burrs and flash from the surface, thereby obtaining a smooth finished product.

[0017] In a further preferred embodiment, the processing equipment in steps one through five is controlled by a PLC programmable controller.

[0018] In a further preferred embodiment, the casting mold described in step four has a cooling channel, and the casting mold is cooled by an external cooling liquid. After the cooling liquid in this step becomes hot, it is transported to the heating platform in step one.

[0019] In a further preferred embodiment, the heating time in step two is 30 minutes, the heating temperature is 1300 degrees Celsius, and the casting mold is heated simultaneously. The casting mold has an electric heating wire inside, which heats the casting mold to a temperature of 150 degrees Celsius, so that the mold is in a preheated state.

[0020] In a further preferred embodiment, step four also includes an exhaust gas purification device, which absorbs and purifies the exhaust gas generated during the mold-opening process to ensure that it meets emission standards.

[0021] In a further preferred embodiment, the waste gas purification equipment is provided with an activated carbon purification layer, a non-woven fabric purification layer, and a purification liquid, and the waste gas is purified by passing through the purification liquid, the non-woven fabric purification layer, and the activated carbon purification layer in sequence.

[0022] (III) Beneficial Effects

[0023] Compared with the prior art, the present invention provides a casting process for valve production, which has the following beneficial effects:

[0024] This invention cleans and dries the billet in the early stage to obtain a clean billet, which improves the purity of the valve during the later manufacturing process and prevents the introduction of impurities. In addition, the cooling liquid becomes hot during the cooling process of the casting mold, and this heat can be utilized by transferring it to the heating platform to keep the heating platform in a heated state, which can effectively utilize the heat. Furthermore, the exhaust gas generated during mold opening is treated by exhaust gas purification equipment so that the exhaust gas can be discharged externally. In addition, the valve casting is shot blasted by a shot blasting machine to remove burrs and flash from the surface, thereby obtaining a smooth finished product. Detailed Implementation

[0025] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. 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 of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0026] Example 1:

[0027] Includes the following steps:

[0028] Step 1: Prepare the billet by cleaning and drying it to obtain a clean billet. Then, weigh the billet to obtain its weight before melting. Finally, place the billet on a heating platform for preheating treatment for 1-2 hours at a temperature of 50-80 degrees Celsius.

[0029] Step 2: Place the clean billet obtained in Step 1 into the melting furnace and heat the billet until it becomes molten. The heating time is 20 minutes and the heating temperature is 1200 degrees. At the same time, heat the casting mold. The casting mold has an electric heating wire inside. The casting mold is heated by the electric heating wire to a temperature of 100 degrees, so that the mold is in a preheated state.

[0030] Step 3: Add a release agent to the mold, then heat the mold to 950 degrees Celsius for 10 minutes. Then pour the molten metal solution from Step 2 into the casting mold and let it stand for 10 minutes.

[0031] Step 4: Test press the casting mold using a casting press for 4-6 minutes, then cool the mold down, and finally demold to obtain the valve casting.

[0032] Step 5: The valve castings obtained in Step 4 are shot blasted and polished for 10-20 minutes to obtain the finished product.

[0033] Step Six: Inspect the finished product obtained in Step Five to check its surface smoothness and compressive strength.

[0034] In this embodiment, in step one, the billet is cleaned and dried using a high-pressure water gun and a hot air dryer to obtain a clean billet.

[0035] In this embodiment, after the finished product passes the inspection in step six, it is packaged, and then the production date and batch number are printed on the packaging box so that customers can clearly know the relevant information of the finished product.

[0036] Example 2:

[0037] A casting process for valve manufacturing includes the following steps:

[0038] Step 1: Prepare the billet by cleaning and drying it to obtain a clean billet. Then, weigh the billet to obtain its weight before melting. Finally, place the billet on a heating platform for preheating.

[0039] Step 2: Place the clean billet obtained in Step 1 into the melting furnace and heat the billet until it becomes molten. The heating time is 50 minutes and the heating temperature is 1450 degrees. At the same time, heat the casting mold. The casting mold has an electric heating wire inside. The casting mold is heated by the electric heating wire to a temperature of 200 degrees, so that the mold is in a preheated state.

[0040] Step 3: Add a release agent to the mold, then heat the mold to 1150 degrees Celsius for 15 minutes. Then pour the molten metal solution from Step 2 into the casting mold and let it stand for 15 minutes.

[0041] Step 4: Test press the casting mold using a casting press for 6 minutes, then cool the mold down, and finally demold to obtain the valve casting.

[0042] Step 5: The valve castings obtained in Step 4 are shot blasted and polished for 20 minutes to obtain the finished product;

[0043] Step Six: Inspect the finished product obtained in Step Five to check its surface smoothness and compressive strength.

[0044] In this embodiment, in step four, the valve casting is shot blasted using a shot blasting machine to remove burrs and flash from the surface, thereby obtaining a smooth finished product.

[0045] In this embodiment, the processing equipment in steps one through five is controlled by a PLC programmable controller.

[0046] In this embodiment, the casting mold in step four has a cooling channel, and the casting mold is cooled by external cooling liquid. After the cooling liquid in this step becomes hot, it is transported to the heating platform in step one.

[0047] Example 3:

[0048] A casting process for valve manufacturing includes the following steps:

[0049] Step 1: Prepare the billet by cleaning and drying it to obtain a clean billet. Then, weigh the billet to obtain its weight before melting. Finally, place the billet on a heating platform for preheating.

[0050] Step 2: Place the clean billet obtained in Step 1 into the melting furnace and heat the billet until it becomes molten. The heating time is 20-50 minutes and the heating temperature is 1200-1450 degrees Celsius. At the same time, heat the casting mold. The casting mold has an electric heating wire inside. The electric heating wire heats the casting mold to a temperature of 100-200 degrees Celsius, so that the mold is in a preheated state.

[0051] Step 3: Add a release agent to the mold, then heat the mold to 950-1150 degrees Celsius for 10-15 minutes. Then pour the molten metal solution from Step 2 into the casting mold and let it stand for 10-15 minutes.

[0052] Step 4: Test press the casting mold using a casting press for 4-6 minutes, then cool the mold down, and finally demold to obtain the valve casting.

[0053] Step 5: The valve castings obtained in Step 4 are shot blasted and polished for 10-20 minutes to obtain the finished product.

[0054] Step Six: Inspect the finished product obtained in Step Five to check its surface smoothness and compressive strength.

[0055] In this embodiment, the heating time in step two is 30 minutes, the heating temperature is 1300 degrees Celsius, and the casting mold is heated simultaneously. The casting mold has an electric heating wire inside, which heats the casting mold to a temperature of 150 degrees Celsius, so that the mold is in a preheated state.

[0056] In this embodiment, step four also includes a waste gas purification device. The waste gas generated during the mold opening process is absorbed and purified by the waste gas purification device to meet the emission standards. The waste gas purification device includes an activated carbon purification layer, a non-woven fabric purification layer, and a purification liquid. The waste gas is purified by passing through the purification liquid, the non-woven fabric purification layer, and the activated carbon purification layer in sequence.

[0057] In all the solutions mentioned above, for connections between two components, welding, bolt and nut connection, bolt or screw connection, or other known connection methods can be selected according to the actual situation. These will not be elaborated here. For all fixed connections mentioned above, welding is preferred. The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A casting process for valve manufacturing, characterized in that, Includes the following steps: Step 1: Prepare the billet by cleaning and drying it to obtain a clean billet. Then, weigh the billet to obtain its weight before melting. Finally, place the billet on a heating platform for preheating. Step 2: Place the clean billet obtained in Step 1 into the melting furnace and heat the billet until it becomes molten. The heating time is 20-50 minutes and the heating temperature is 1200-1450 degrees Celsius. At the same time, heat the casting mold. The casting mold has an electric heating wire inside. The electric heating wire heats the casting mold to a temperature of 100-200 degrees Celsius, so that the mold is in a preheated state. Step 3: Add a release agent to the mold, then heat the mold to 950-1150 degrees Celsius for 10-15 minutes. Then pour the molten metal solution from Step 2 into the casting mold and let it stand for 10-15 minutes. Step 4: Test press the casting mold using a casting press for 4-6 minutes, then cool the mold down, and finally demold to obtain the valve casting. Step 5: The valve castings obtained in Step 4 are shot blasted and polished for 10-20 minutes to obtain the finished product. Step Six: Inspect the finished product obtained in Step Five to check its surface smoothness and compressive strength.

2. The casting process for valve production according to claim 1, characterized in that: The preheating time in step one is 1-2 hours, and the preheating temperature is 50-80 degrees Celsius.

3. The casting process for valve production according to claim 1, characterized in that: In step one, the billet is cleaned and dried using a high-pressure water gun and a hot air dryer to obtain a clean billet.

4. The casting process for valve production according to claim 1, characterized in that: After the finished product passes inspection in step six, it is packaged, and the production date and batch number are printed on the packaging box so that customers can clearly know the relevant information of the finished product.

5. The casting process for valve production according to claim 1, characterized in that: In step four, the valve castings are shot blasted using a shot blasting machine to remove burrs and flash from the surface, resulting in a smooth finished product.

6. The casting process for valve production according to claim 1, characterized in that: The processing equipment in steps one through five is controlled by a PLC programmable controller.

7. The casting process for valve production according to claim 3, characterized in that: The casting mold described in step four has a cooling channel, and the casting mold is cooled by external cooling liquid. After the cooling liquid in this step becomes hot, it is transported to the heating platform in step one.

8. The casting process for valve production according to claim 1, characterized in that: In step two, the heating time is 30 minutes and the heating temperature is 1300 degrees Celsius. At the same time, the casting mold is heated. The casting mold has an electric heating wire inside, which heats the casting mold to a temperature of 150 degrees Celsius, so that the mold is in a preheated state.

9. The casting process for valve production according to claim 1, characterized in that: Step four also includes an exhaust gas purification device, which absorbs and purifies the exhaust gas generated during the mold opening process to meet emission standards.

10. The casting process for valve production according to claim 9, characterized in that: The waste gas purification equipment is equipped with an activated carbon purification layer, a non-woven fabric purification layer, and a purification liquid. The waste gas is purified by passing through the purification liquid, the non-woven fabric purification layer, and the activated carbon purification layer in sequence.