A new method for making a cold iron surface flat quickly

Abstract

The present application relates to the technical field of cold iron processing for casting production, and particularly relates to a novel cold iron surface rapid flattening manufacturing method, which comprises the following steps: pre-polishing the concave-convex cold iron fitting surface, determining the cold iron fitting curvature according to the casting fitting curvature, determining the resin binder thickness in combination with the cold iron fitting curvature and the actual roughness of the cold iron fitting surface; determining the target surface roughness according to the coated sand gap width, and coating the target resin binder thickness to the cold iron fitting surface and infiltrating; pre-hardening at room temperature, baking and curing, detecting the sand layer compactness and adjusting the sand laying vibration frequency, and readjusting the target surface roughness if the compactness is still not up to the standard. The present application determines the sand layer compactness of the sand layer by adjusting the resin binder thickness and the surface roughness of the cold iron fitting surface, and solves the problem that the coated sand layer on the cold iron fitting surface is easy to be lost and dropped in the quenching process.

Description

Technical Field

[0001] This invention relates to the field of chill processing technology for casting production, and in particular to a novel method for rapidly smoothing the surface of chills. Background Technology

[0002] In the casting production process, chills serve as the core quenching agent, regulating the solidification temperature field of the casting, accelerating the cooling rate of specific parts, and thus optimizing the casting's microstructure and properties. Currently, the mainstream types of chills on the market include graphite chills, round steel chills, and cast iron chills. Graphite chills offer gentle quenching and high thermal conductivity, but have low strength and high processing costs, making them only suitable for mass-produced critical castings. Round steel chills have poor thermal conductivity, weak quenching effect, and are prone to deformation and oxidation, limiting their application scenarios. Cast iron chills, due to their good thermal conductivity, strong quenching ability, low manufacturing cost, and ability to be made into complex shapes, have become the most widely used type in industrial production. However, cast iron chills have an inherent weakness in strength, making them prone to deformation and impacts during transportation, storage, and use, leading to surface defects such as missing material and unevenness. Existing solutions to this problem are diverse, but all have significant limitations. Some employ mechanical polishing processes, requiring multiple steps, which are not only cumbersome and time-consuming but also have limited effectiveness in repairing severely defective chills. Another method involves chemical polishing to dissolve surface irregularities. While this is highly efficient, it requires strict control over the chemical reagent ratios and processing time, posing environmental risks and incurring high costs. Traditional scraping processes rely on manual operation, demanding highly skilled technicians, resulting in low repair efficiency and failing to meet the needs of large-scale production.

[0003] Chinese Patent Publication No. CN116493565A discloses a method for forming sand-coated chills in sand casting. This method is used for forming a worktable in sand casting and relates to the technical field of sand casting methods. Specifically, it includes: S1, preparing coated sand; S2, molding N sand-separating plates from the coated sand, with the front of the sand-separating plates flat as the base surface and the back as the first placement surface for placing chills; S3, with the first placement surface of the sand-separating plates facing upwards, arranging the N sand-separating plates in a rectangular array, so that the base surfaces are joined to form a worktable; S4, designing and manufacturing chills that can be accommodated on the sand-separating plates according to the dimensions of the first placement surface; S5, placing the chills sequentially on the first placement surface of the sand-separating plates; S6, flipping all the sand-separating plates so that the worktable formed by the joined base surfaces faces upwards. This invention uses sand-separating plates to position and place chills evenly, and the worktable formed by the sand-separating plates has better overall integrity, resulting in a better surface finish of the cast parts. It also allows for direct replacement, improving efficiency and practicality.

[0004] It is evident that the existing technology has the following problems: when cooling castings with curved surfaces, the lack of a process to adjust the density of the sand layer on the chilled iron bonding surface by adjusting the thickness of the resin adhesive and the surface roughness of the chilled iron bonding surface makes the sand layer on the chilled iron bonding surface prone to loss and falling off during the rapid cooling process. Summary of the Invention

[0005] Therefore, the present invention provides a novel method for rapidly smoothing the surface of chills, which overcomes the problem in the prior art that, when cooling castings with curved surfaces, the lack of a process to adjust the density of the sand layer on the chill bonding surface by adjusting the thickness of the resin adhesive and the surface roughness of the chill bonding surface leads to the easy loss and fall-off of the sand layer on the chill bonding surface during the rapid cooling process.

[0006] To achieve the above objectives, the present invention provides a novel method for rapidly smoothing the surface of chills, comprising: Roughness pre-grinding is performed on the uneven surface of the target chill bonding surface; The curvature of the chill's mating surface is determined based on the radius of curvature of the mating surface of the target casting, and the thickness of the target resin adhesive is determined based on the curvature of the chill's mating surface and the actual surface roughness of the target chill's mating surface. The target surface roughness is determined based on the target resin adhesive thickness and the target coated sand pore width. Apply and impregnate the chilled iron bonding surface with the resin adhesive according to the target resin adhesive thickness; Combine the tool kit with the chilled iron contact surface according to the width of the coated sand gaps to lay the coated sand in layers into the coated sand gaps; The pre-hardened coated sand chill is baked to ensure uniform curing of the coated sand. The density of each layer of coated sand after curing is tested, and the vibration frequency during the layer laying process is adjusted based on the density of the sand layer. If the density of the sand layer is still not up to standard after adjusting the vibration frequency, then adjust the target surface roughness. The target coating sand void width is the preset coating sand thickness that is bonded to the chilled iron bonding surface.

[0007] Furthermore, the process of determining the thickness of the resin adhesive includes: The thickness of the reference resin adhesive is determined based on the curvature of the cold iron bonding surface, and the thickness of the target resin adhesive is determined based on the reference resin adhesive thickness and the actual surface roughness. The thickness of the target resin adhesive is positively correlated with the actual surface roughness.

[0008] Furthermore, the process of determining the target surface roughness includes: The resin thickness ratio is determined based on the resin adhesive thickness and the target coated sand void width. The surface roughness is adjusted to obtain the target surface roughness based on the comparison between the resin thickness ratio and the resin thickness ratio threshold range. The resin thickness ratio is used to characterize the reasonableness of the matching between the resin adhesive thickness and the target coated sand void width.

[0009] Furthermore, the process of adjusting the surface roughness to obtain the target surface roughness includes: Since the resin thickness ratio is less than the minimum value of the resin thickness ratio threshold range, the actual roughness is increased based on the difference between the minimum value of the resin thickness ratio threshold range and the resin thickness ratio, so as to increase the adhesion of the resin adhesive to the target chill bonding surface. Based on the resin thickness ratio being within the resin thickness ratio threshold range, the current surface roughness is maintained to maintain the adhesion of the resin adhesive to the target chill bonding surface; Based on the fact that the resin thickness ratio is greater than the maximum value of the resin thickness ratio threshold range, the surface roughness is reduced according to the difference between the resin thickness ratio and the maximum value of the resin thickness ratio threshold range, so as to reduce the adhesion of the resin adhesive to the target chill bonding surface.

[0010] Furthermore, the process of layering the coated sand into the voids of the coated sand includes: Determine the arc orientation of the sand layer gap assembly, fill the lateral sand layer gap perpendicular to the arc orientation with coated sand, determine the number of coated sand layers based on the single layer filling height, and determine the vibration frequency corresponding to the number of coated sand layers based on the number of coated sand layers. The sand layer gap assembly is a component formed by combining the tool set with the chilled iron contact surface.

[0011] Furthermore, the process of determining the vibration frequency corresponding to the number of laying layers includes: The initial vibration frequency is determined based on the initial coating sand laying height and resin adhesive thickness, and the vibration frequency corresponding to the next layer laying number is determined based on the settlement height of the coating sand caused by the initial vibration frequency. The settlement height is the height that decreases after the initial covered sand laying height is vibrated at the initial vibration frequency, and the vibration frequency is positively correlated with the settlement height.

[0012] Furthermore, the process of baking the pre-hardened coated sand chill at room temperature includes: Based on the sand layer gap assembly after the coated sand is laid, the initial hardening time is determined according to the target coated sand gap width, and the initial hardening time is adjusted according to the number of coated sand layers to obtain the target hardening time; Among them, the hardening time is positively correlated with the number of layers of coated sand.

[0013] Furthermore, the process of testing the density of each layer of coated sand after curing includes: The porosity of each layer of coated sand is detected, and the density of the corresponding layer of sand is determined based on the porosity.

[0014] Furthermore, the process of adjusting the vibration frequency during the layered laying process includes: The vibration frequency is adjusted based on the density deviation of the sand layer to ensure uniform sand coating. Among them, the vibration frequency is positively correlated with the sand layer compaction deviation value, which is the difference between the measured sand layer compaction and the preset target sand layer compaction value.

[0015] Furthermore, the process of adjusting the roughness of the target surface includes: The surface roughness of the target is increased by increasing the density deviation value of the sand layer in order to improve the adhesion of the resin adhesive to the target chill bonding surface.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: In implementation, by selecting the radius of curvature of the bonding surface of the target casting to determine the curvature of the chill bonding surface, and by determining the thickness of the target resin adhesive according to the curvature of the chill bonding surface, the thickness of the resin adhesive can be adapted to the corresponding curvature of the chill bonding surface, avoiding the filling of the coating sand voids due to excessive or insufficient resin adhesive thickness, which would affect the curing firmness of the coating sand layer; by adjusting the vibration frequency of the layered laying of the coating sand, the coating sand can maintain a certain degree of density during the laying process, ensuring the firmness of the subsequent coating sand layer; in cases where the density of the sand layer is still unqualified after adjusting the vibration frequency, the adhesion of the resin adhesive to the chill bonding surface can be adjusted by adjusting the target surface roughness, forming a complete set of preparation logic for preparing the coating sand layer of the chill bonding surface.

[0017] Furthermore, in practice, determining the reference resin adhesive thickness by the curvature of the chilled iron bonding surface ensures that a resin adhesive thickness corresponding to a specific chilled iron bonding surface curvature is obtained, keeping the resin adhesive thickness at an appropriate level and avoiding excessive resin adhesive in subsequent coating sanding steps and waste of resin adhesive. Determining the target resin adhesive thickness by combining the reference resin adhesive thickness with the actual surface roughness allows for a more accurate determination of the resin adhesive thickness that meets the specific chilled iron bonding surface curvature.

[0018] Furthermore, in implementation, if the resin thickness ratio is less than the minimum value of the resin thickness ratio threshold range, the actual roughness is increased based on the difference between the minimum value and the resin thickness ratio threshold range. This increases the adhesion of the resin adhesive to the target chill bonding surface. Increasing the surface roughness of the chill bonding surface enhances the adhesion of the resin adhesive, preventing the resin adhesive from being too thin and failing to form an effective thickness. Conversely, if the resin thickness ratio is greater than the maximum value of the resin thickness ratio threshold range, the surface roughness is decreased based on the difference between the resin thickness ratio and the maximum value of the resin thickness ratio threshold range. This reduces the adhesion of the resin adhesive to the target chill bonding surface, preventing the resin adhesive from being too thick and affecting the subsequent coating sand laying effect.

[0019] Furthermore, in implementation, by limiting the filling of coated sand from the lateral gap perpendicular to the concave arc, it is possible to avoid the accumulation of coated sand caused by direct feeding from the concave arc surface, thus reducing the efficiency of coated sand laying; matching the single-layer filling height according to the sand layer gap can avoid the decrease in sand laying efficiency caused by the increase in vibration time due to excessive single-layer filling height; the vibration frequency increases with the number of coated sand layers, and the more layers of coated sand laid, the higher the vibration frequency, which can avoid the defects of insufficient compaction due to the attenuation of vibration energy of the upper layer of sand at a fixed frequency, and ensure the uniform density of coated sand.

[0020] Furthermore, in implementation, the initial vibration frequency is determined by the initial height of the coated sand and the thickness of the resin adhesive. On the one hand, this avoids excessive vibration intensity causing the resin adhesive to be subjected to excessive friction from the coated sand, resulting in excessive temperature rise and premature curing. On the other hand, it ensures that the coated sand layer is laid densely without affecting the thickness of the resin adhesive. The vibration frequency corresponding to the number of layers to be laid is determined based on the settlement height of the coated sand caused by the initial vibration frequency. This can compensate for the settlement height caused by the mutual compression of coated sand particles, which leads to an increase in compaction resistance. The vibration energy loss is made up layer by layer, and each layer of coated sand can achieve the preset density.

[0021] Furthermore, in implementation, determining the initial hardening time by the target coating sand void width can avoid uneven overall hardening caused by the resin adhesive near the center of the target coating sand voids hardening first. The initial hardening time is adjusted according to the number of coating sand layers so that the hardening time matches the number of coating sand layers, avoiding incomplete hardening of the coating sand layer due to too many coating sand layers.

[0022] Furthermore, in implementation, by determining the target sand layer density according to the chilling process requirements, the chiller can stably transmit the chilling capacity and avoid interference with the chilling effect due to insufficient sand layer density. By adjusting the vibration frequency through the sand layer density deviation value, the sand layer density can be guaranteed to meet the subsequent chilling effect and avoid insufficient bonding strength between the chiller bonding surface and the coated sand due to insufficient sand layer density. Attached Figure Description

[0023] Figure 1 This is a flowchart of the method for rapidly smoothing the surface of the novel chill in this embodiment; Figure 2 This is a flowchart of the process for grinding the surface of the chill in this embodiment; Figure 3 This is a flowchart illustrating the process of adjusting the target surface roughness in this embodiment; Figure 4 This is a flowchart illustrating the process of adjusting the vibration frequency during the layered laying process in this embodiment. Detailed Implementation

[0024] To make the objectives and advantages of the present invention clearer, the present invention will be further described below with reference to embodiments; it should be understood that the specific embodiments described herein are merely for explaining the present invention and are not intended to limit the present invention.

[0025] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0026] It should be noted that in the description of this invention, the terms "upper", "lower", "left", "right", "inner", "outer", etc., which indicate directions or positional relationships, are based on the directions or positional relationships shown in the accompanying drawings. This is only for the convenience of description and is not intended to indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation of this invention.

[0027] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0028] Please see Figure 1 As shown, it is a flowchart of the manufacturing method for rapidly flattening the surface of the novel chill in this embodiment; This invention provides a novel method for rapidly smoothing the surface of chills, comprising: Step S1: Pre-polish the roughness of the uneven target chill bonding surface; Step S2: Determine the curvature of the chill's mating surface based on the radius of curvature of the mating surface of the target casting; determine the thickness of the target resin adhesive based on the curvature of the chill's mating surface and the actual surface roughness of the target chill's mating surface. Step S3: Determine the target surface roughness based on the target resin adhesive thickness and the target coated sand void width; Step S4: Apply and impregnate the cold iron bonding surface with the resin adhesive according to the target resin adhesive thickness; Step S5: Combine the tool kit with the chilled iron bonding surface according to the width of the coated sand gaps to lay the coated sand in layers into the coated sand gaps. Step S6: Bake the pre-hardened coated sand chill at room temperature to uniformly solidify the coated sand. Step S7: Detect the density of each layer of coated sand after curing, and adjust the vibration frequency during the layer laying process based on the density of the sand layer. Step S8: If the density of the sand layer is still not up to standard after adjusting the vibration frequency, then adjust the target surface roughness. The target coating sand void width is the preset coating sand thickness that is bonded to the chilled iron bonding surface.

[0029] In this embodiment of the invention, in step S1, the chills that deform during the rapid cooling process of the curved casting, resulting in uneven surfaces, need to be pre-polished. Please see Figure 2 As shown, it is a flowchart of the process of grinding the surface of the chill in this embodiment; This embodiment provides a process for grinding the surface of a chill, including: Step S10: Apply degreasing agent to the chill to wet and wipe the oil stains on the surface of the chill, and blow it dry; Step S11: Polish the oxide layer and black edges on the dried cold iron surface; Step S12: Remove iron filings and dust from the surface of the cold iron using a high-pressure air gun, and perform a second wiping.

[0030] In practice, the curvature of the chill bonding surface is determined by selecting the radius of curvature of the target casting's bonding surface, and the thickness of the target resin adhesive is determined based on the curvature of the chill bonding surface. This ensures that the resin adhesive thickness matches the corresponding chill bonding surface curvature, preventing the subsequent coating sand from filling the gaps due to excessively thick or thin resin adhesive, which would affect the curing firmness of the coating sand layer. By adjusting the vibration frequency of the layered coating sand, a certain degree of sand layer density can be maintained during the laying process, ensuring the firmness of the subsequent coating sand layer. If the sand layer density is still unsatisfactory after adjusting the vibration frequency, the adhesion of the resin adhesive to the chill bonding surface is adjusted by adjusting the target surface roughness, forming a complete preparation logic for preparing the coating sand layer of the chill bonding surface.

[0031] Specifically, the process of determining the thickness of the resin adhesive includes: The thickness of the reference resin adhesive is determined based on the curvature of the cold iron bonding surface, and the thickness of the target resin adhesive is determined based on the reference resin adhesive thickness and the actual surface roughness. The thickness of the target resin adhesive is positively correlated with the actual surface roughness.

[0032] It is understandable that, during the chilling process of the curved casting, the chilling surface needs to be in close contact with the curved casting surface, so the curvature of the chilling surface needs to be consistent with that of the curved casting surface.

[0033] In this embodiment of the invention, firstly, the thickness of the reference resin adhesive is determined by the curvature of the chill bonding surface. Since the bonding surface of the curved casting is convex, the chill bonding surface is concave. When applying resin adhesive to the concave chill bonding surface, due to gravity, the resin adhesive applied to both sides will accumulate towards the center of the concave surface. Therefore, the thickness of the reference resin adhesive needs to be determined by the curvature of the chill bonding surface, and the thickness of the reference resin adhesive is negatively correlated with the curvature of the chill bonding surface.

[0034] In this embodiment, since the surface of the chill is a concave curved surface, the two sides of the chill are grasped and immersed in the resin adhesive so that the entire chill is quickly coated with the resin adhesive, thereby improving the preparation efficiency.

[0035] After determining the reference resin adhesive thickness, the reference resin adhesive thickness is adjusted based on the actual surface roughness of the chilled iron bonding surface to obtain the target resin adhesive thickness. This avoids excessive resin adhesive in subsequent coating sanding steps and also avoids waste of resin adhesive. The target resin adhesive thickness is positively correlated with the actual surface roughness; the greater the surface roughness of the chilled iron bonding surface, the stronger the adhesion of the resin adhesive to the chilled iron bonding surface.

[0036] In practice, determining the reference resin adhesive thickness by the curvature of the chilled iron bonding surface ensures that the resin adhesive thickness corresponds to the specific curvature of the chilled iron bonding surface, keeping the resin adhesive thickness at an appropriate level and avoiding excessive resin adhesive in subsequent coating sanding steps and waste of resin adhesive. Determining the target resin adhesive thickness by combining the reference resin adhesive thickness with the actual surface roughness allows for a more accurate determination of the resin adhesive thickness that meets the specific curvature of the chilled iron bonding surface.

[0037] Specifically, the process of determining the target surface roughness includes: The resin thickness ratio is determined based on the resin adhesive thickness and the target coated sand void width. The surface roughness is adjusted to obtain the target surface roughness based on the comparison between the resin thickness ratio and the resin thickness ratio threshold range. The resin thickness ratio is used to characterize the reasonableness of the matching between the resin adhesive thickness and the target coated sand void width.

[0038] In this embodiment of the invention, the target coated sand void width is the preset thickness of the coated sand layer, which is determined according to the chill requirements of the casting to ensure the uniform chilling effect on the casting.

[0039] It is understandable that the purpose of determining the resin thickness ratio based on the resin adhesive thickness and the target coated sand void width is only to characterize the reasonableness of the matching between the resin adhesive thickness and the target coated sand void width. That is, under the determined target coated sand void width, the resin adhesive thickness should not be too thick to affect the subsequent coating sand filling process, nor should the resin adhesive thickness be too thin to prevent the coating sand from bonding tightly with the chilled iron bonding surface.

[0040] Please see Figure 3 As shown, it is a flowchart of the process of adjusting the roughness of the target surface in this embodiment; Specifically, the process of adjusting surface roughness to obtain the target surface roughness includes: Since the resin thickness ratio is less than the minimum value of the resin thickness ratio threshold range, the actual roughness is increased based on the difference between the minimum value of the resin thickness ratio threshold range and the resin thickness ratio, so as to increase the adhesion of the resin adhesive to the target chill bonding surface. Based on the resin thickness ratio being within the resin thickness ratio threshold range, the current surface roughness is maintained to maintain the adhesion of the resin adhesive to the target chill bonding surface; Based on the fact that the resin thickness ratio is greater than the maximum value of the resin thickness ratio threshold range, the surface roughness is reduced according to the difference between the resin thickness ratio and the maximum value of the resin thickness ratio threshold range, so as to reduce the adhesion of the resin adhesive to the target chill bonding surface.

[0041] In this embodiment of the invention, when the resin thickness ratio is less than the minimum value of the resin thickness ratio threshold range, it indicates that the resin layer thickness is insufficient to completely fill the rough pits on the surface of the chill, and the resin layer cannot form an effective adhesion to the bonding surface of the chill; when the resin thickness ratio is greater than the maximum value of the resin thickness ratio threshold range, it indicates that the resin thickness far exceeds the height of the unevenness on the surface of the chill, and the excess resin accumulates to form an excessively thick resin layer, causing adhesion and increasing the internal stress, which increases the cracking of the resin layer.

[0042] The difference between the minimum value of the resin thickness ratio threshold range and the resin thickness ratio indicates the degree of deficiency of the current resin thickness relative to the critical minimum bonding requirement. The greater the difference between the minimum value of the resin thickness ratio threshold range and the resin thickness ratio, the larger the gap in resin filling the roughness pits.

[0043] The difference between the resin thickness ratio and the maximum value of the resin thickness ratio threshold range can characterize the current excess amount of resin relative to the maximum value of the resin thickness ratio threshold range. The larger the difference between the resin thickness ratio and the maximum value of the resin thickness ratio threshold range, the thicker the resin adhesive is.

[0044] In implementation, if the resin thickness ratio is less than the minimum value of the resin thickness ratio threshold range, the actual roughness is increased based on the difference between the minimum value and the resin thickness ratio threshold range. This increases the adhesion of the resin adhesive to the target chill bonding surface. Increasing the surface roughness of the chill bonding surface improves the adhesion of the resin adhesive, preventing the resin adhesive from being too thin and failing to form an effective thickness. If the resin thickness ratio is greater than the maximum value of the resin thickness ratio threshold range, the surface roughness is decreased based on the difference between the resin thickness ratio and the maximum value of the resin thickness ratio threshold range. This decreases the adhesion of the resin adhesive to the target chill bonding surface. Reducing the surface roughness weakens the adhesion of the resin adhesive to the chill bonding surface, preventing the resin adhesive from being too thick and affecting the subsequent coating sand laying effect.

[0045] Specifically, the process of laying the coated sand in layers into the voids of the coated sand includes: Determine the arc orientation of the sand layer gap assembly, fill the lateral sand layer gap perpendicular to the arc orientation with coated sand, determine the number of coated sand layers based on the single layer filling height, and determine the vibration frequency corresponding to the number of coated sand layers based on the number of coated sand layers. The sand layer gap assembly is a component formed by combining the tool set with the chilled iron contact surface.

[0046] In this embodiment of the invention, the contact surface of the chill is a concave arc, and the combination of the tooling and the chill with the concave arc contact surface is a sand layer gap assembly.

[0047] It is understandable that when laying coated sand, the sand layer gap assembly is sealed on one side perpendicular to the arc direction, and coated sand is laid on the other side.

[0048] The number of coating sand layers is determined by the single-layer sand filling height. The single-layer sand filling height needs to be determined according to the gap of the sand layer gap assembly. The single-layer sand filling height is positively correlated with the gap. If the single-layer sand filling height is too high, it will cause the vibration time to be prolonged during subsequent layer laying vibration, resulting in a reduction in the efficiency of coating sand layer preparation.

[0049] It is understandable that the vibration frequency is positively correlated with the number of layers of coated sand. As the number of coated sand layers increases, the vibration effect of the same vibration frequency on the upper layer of coated sand is lower than that on the lower layer.

[0050] In practice, by limiting the filling of coated sand from the lateral gap perpendicular to the concave arc, it is possible to avoid the accumulation of coated sand caused by direct feeding from the concave arc surface, which would reduce the efficiency of coated sand laying. Matching the single-layer filling height according to the gap between sand layers can avoid the decrease in sand laying efficiency caused by the increase in vibration time due to excessive single-layer filling height. The vibration frequency increases with the number of coated sand layers. The more layers of coated sand laid, the higher the vibration frequency. This can avoid the defects of insufficient compaction due to the attenuation of vibration energy of the upper layer of sand at a fixed frequency, and ensure the uniform density of the coated sand.

[0051] Specifically, the process of determining the vibration frequency corresponding to the number of laying layers includes: The initial vibration frequency is determined based on the initial coating sand laying height and resin adhesive thickness, and the vibration frequency corresponding to the next layer laying number is determined based on the settlement height of the coating sand caused by the initial vibration frequency. The settlement height is the height that decreases after the initial covered sand laying height is vibrated at the initial vibration frequency, and the vibration frequency is positively correlated with the settlement height.

[0052] In this embodiment of the invention, the initial vibration frequency is determined by the initial coating sand laying height and the resin adhesive thickness. This ensures that the initial vibration frequency does not affect the resin adhesive thickness, and that the coating sand layer is laid densely when the coating sand is first applied.

[0053] During the laying of the coated sand, the settlement height of the previous layer is used as the feedback basis for the current coated sand layer. The higher the vibration frequency, the more fully the coated sand particles are squeezed together, the greater the settlement height, and the greater the load of the upper coated sand accumulation. The settlement attenuates at the same vibration frequency, so the frequency is gradually increased to make the coated sand layer denser.

[0054] In implementation, the initial vibration frequency is determined by the initial height of the coated sand and the thickness of the resin adhesive. On the one hand, this avoids excessive vibration intensity, which could cause the resin adhesive to be subjected to excessive friction from the coated sand, resulting in excessive temperature rise and premature curing. On the other hand, it ensures that the coated sand layer is laid densely without affecting the thickness of the resin adhesive. The vibration frequency corresponding to the number of layers to be laid is determined based on the settlement height of the coated sand caused by the initial vibration frequency. This can compensate for the settlement height caused by the mutual compression of coated sand particles, which leads to an increase in compaction resistance. The vibration energy loss is made up layer by layer, and each layer of coated sand can achieve the preset density.

[0055] Specifically, the baking process for the pre-hardened coated sand chill at room temperature includes: Based on the sand layer gap assembly after the coated sand is laid, the initial hardening time is determined according to the target coated sand gap width, and the initial hardening time is adjusted according to the number of coated sand layers to obtain the target hardening time; Among them, the hardening time is positively correlated with the number of layers of coated sand.

[0056] Understandably, the wider the pore width of the target coated sand, the more uniformly the resin adhesive and the coated sand layer formed by vibration are mixed, and the longer the hardening time is required.

[0057] In this embodiment of the invention, the more layers of coated sand are laid, the longer the total vibration time of the coated sand layer, the denser the coated sand layer, and the longer the hardening time is required to fully harden the coated sand layer.

[0058] In practice, the initial curing time is determined by the target coating sand void width. This can prevent uneven overall curing caused by the resin adhesive near the center of the target coating sand void curing first. The initial curing time is adjusted according to the number of coating sand layers so that the curing time matches the number of coating sand layers, avoiding incomplete curing of the coating sand layer due to too many coating sand layers.

[0059] Specifically, the process of testing the density of each layer of coated sand after curing includes: The porosity of each layer of coated sand is detected, and the density of the corresponding layer of sand is determined based on the porosity.

[0060] It is understandable that by detecting the porosity of each layer of coated sand, the density of the corresponding layer of sand can be characterized. The higher the porosity, the better the density of the sand layer, and vice versa.

[0061] Please see Figure 4 As shown, it is a flowchart of the process of adjusting the vibration frequency during the layered laying process in this embodiment; Specifically, the process of adjusting the vibration frequency during the layered laying process includes: The vibration frequency is adjusted based on the density deviation of the sand layer to ensure uniform sand coating. Among them, the vibration frequency is positively correlated with the sand layer compaction deviation value, which is the difference between the measured sand layer compaction and the preset target sand layer compaction value.

[0062] In this embodiment of the invention, the density of the target sand layer is determined according to a preset requirement that can meet the chilling requirements of the chilled iron bonding surface to the cast iron bonding surface during the chilling process. The sand layer compaction deviation value can characterize the degree of deviation between the current compaction effect of the coated sand layer and the standard compaction requirements; When the sand layer compaction deviation value is within the threshold range of the sand layer compaction deviation value, it means that the sand layer compaction fully meets the standard. When the density deviation value of the sand layer is greater than the maximum value of the threshold range of the density deviation value of the sand layer, it means that the film-coated sand layer is over-compacted and the sand particles are squeezed too tightly, and the vibration frequency needs to be reduced accordingly. When the density deviation value of the sand layer is less than the minimum value of the threshold range of the density deviation value of the sand layer, it means that the coated sand layer is not compacted enough, there are many internal pores, and the bonding strength between the chill and the coated sand is not strong enough. The vibration frequency needs to be increased accordingly. In this embodiment of the invention, the chilled iron with the coated sand layer laid on it is placed in a baking oven and baked at 200°C for 30 minutes to solidify the coated sand layer.

[0063] In implementation, the target sand layer density is determined by the chilling process requirements, which can ensure the chiller can stably transmit the chilling capacity and avoid the chilling effect being interfered with due to insufficient sand layer density. By adjusting the vibration frequency by the sand layer density deviation value, it can be ensured that the sand layer density meets the subsequent chilling effect and avoid insufficient bonding strength between the chiller bonding surface and the coated sand due to insufficient sand layer density.

[0064] Specifically, the process of adjusting the roughness of the target surface includes: The surface roughness of the target is increased by increasing the density deviation value of the sand layer in order to improve the adhesion of the resin adhesive to the target chill bonding surface.

[0065] In this embodiment of the invention, by increasing the target surface roughness by the sand layer compaction deviation value, the extent to which the current compaction degree of the coated sand layer deviates from the qualified range can be characterized. When the compaction gap of the coated sand cannot be compensated by adjusting the vibration frequency alone, it is necessary to increase the surface roughness of the chill bonding surface to enhance the adhesion of the resin adhesive to the coated sand and chill bonding surface.

[0066] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after these changes or substitutions will all fall within the scope of protection of the present invention.

[0067] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A novel method for rapidly smoothing the surface of chilled iron, characterized in that, include: Roughness pre-grinding is performed on the uneven surface of the target chill bonding surface; The curvature of the chill's mating surface is determined based on the radius of curvature of the mating surface of the target casting, and the thickness of the target resin adhesive is determined based on the curvature of the chill's mating surface and the actual surface roughness of the target chill's mating surface. The target surface roughness is determined based on the target resin adhesive thickness and the target coated sand pore width. Apply and impregnate the chilled iron bonding surface with the resin adhesive according to the target resin adhesive thickness; Combine the tool kit with the chilled iron contact surface according to the width of the coated sand gaps to lay the coated sand in layers into the coated sand gaps; The pre-hardened coated sand chill is baked to ensure uniform curing of the coated sand. The density of each layer of coated sand after curing is tested, and the vibration frequency during the layer laying process is adjusted based on the density of the sand layer. If the density of the sand layer is still not up to standard after adjusting the vibration frequency, then adjust the target surface roughness. The target coating sand void width is the preset coating sand thickness that is bonded to the chilled iron bonding surface.

2. The method for rapidly smoothing the surface of a novel chilled iron according to claim 1, characterized in that, The process of determining the thickness of the resin adhesive includes: The thickness of the reference resin adhesive is determined based on the curvature of the cold iron bonding surface, and the thickness of the target resin adhesive is determined based on the reference resin adhesive thickness and the actual surface roughness. The thickness of the target resin adhesive is positively correlated with the actual surface roughness.

3. The method for rapidly smoothing the surface of a novel chilled iron according to claim 2, characterized in that, The process of determining the target surface roughness includes: The resin thickness ratio is determined based on the resin adhesive thickness and the target coated sand void width. The surface roughness is adjusted to obtain the target surface roughness based on the comparison between the resin thickness ratio and the resin thickness ratio threshold range. The resin thickness ratio is used to characterize the reasonableness of the matching between the resin adhesive thickness and the target coated sand void width.

4. The method for rapidly smoothing the surface of a novel chilled iron according to claim 3, characterized in that, The process of adjusting surface roughness to obtain the target surface roughness includes: Since the resin thickness ratio is less than the minimum value of the resin thickness ratio threshold range, the actual roughness is increased based on the difference between the minimum value of the resin thickness ratio threshold range and the resin thickness ratio, so as to increase the adhesion of the resin adhesive to the target chill bonding surface. Based on the resin thickness ratio being within the resin thickness ratio threshold range, the current surface roughness is maintained to maintain the adhesion of the resin adhesive to the target chill bonding surface; Based on the fact that the resin thickness ratio is greater than the maximum value of the resin thickness ratio threshold range, the surface roughness is reduced according to the difference between the resin thickness ratio and the maximum value of the resin thickness ratio threshold range, so as to reduce the adhesion of the resin adhesive to the target chill bonding surface.

5. The method for rapidly smoothing the surface of a novel chilled iron according to claim 4, characterized in that, The process of laying coated sand in layers into the voids of the coated sand includes: Determine the arc orientation of the sand layer gap assembly, fill the lateral sand layer gap perpendicular to the arc orientation with coated sand, determine the number of coated sand layers based on the single layer filling height, and determine the vibration frequency corresponding to the number of coated sand layers based on the number of coated sand layers. The sand layer gap assembly is a component formed by combining the tool set with the chilled iron contact surface.

6. The method for rapidly smoothing the surface of a novel chilled iron according to claim 5, characterized in that, The process of determining the vibration frequency corresponding to the number of laying layers includes: The initial vibration frequency is determined based on the initial coating sand laying height and resin adhesive thickness, and the vibration frequency corresponding to the next layer laying number is determined based on the settlement height of the coating sand caused by the initial vibration frequency. The settlement height is the height that decreases after the initial covered sand laying height is vibrated at the initial vibration frequency, and the vibration frequency is positively correlated with the settlement height.

7. The method for rapidly smoothing the surface of a novel chilled iron according to claim 6, characterized in that, The baking process for pre-hardened coated sand chills at room temperature includes: Based on the sand layer gap assembly after the coated sand is laid, the initial hardening time is determined according to the target coated sand gap width, and the initial hardening time is adjusted according to the number of coated sand layers to obtain the target hardening time; Among them, the hardening time is positively correlated with the number of layers of coated sand.

8. The method for rapidly smoothing the surface of a novel chilled iron according to claim 7, characterized in that, The process of testing the density of each layer of coated sand after curing includes: The porosity of each layer of coated sand is detected, and the density of the corresponding layer of sand is determined based on the porosity.

9. The method for rapidly smoothing the surface of a novel chilled iron according to claim 8, characterized in that, The process of adjusting the vibration frequency during the layered laying process includes: The vibration frequency is adjusted based on the density deviation of the sand layer to ensure uniform sand coating. Among them, the vibration frequency is positively correlated with the sand layer compaction deviation value, which is the difference between the measured sand layer compaction and the preset target sand layer compaction value.

10. The method for rapidly smoothing the surface of a novel chilled iron according to claim 9, characterized in that, The process of adjusting the surface roughness of the target includes: The surface roughness of the target is increased by increasing the density deviation value of the sand layer in order to improve the adhesion of the resin adhesive to the target chill bonding surface.

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