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球墨铸铁管件常用生产工艺特点

作者: -1    发布时间: 2018-07-26    次浏览
球墨铸铁管件常用生产工艺特点之黏土砂铸造工艺
The clay sand casting process of ductile iron pipe fittings is commonly used

黏土砂是以黏土(陶土)作黏结剂的型(芯)砂。黏土砂造型由于其生产成本低廉,所以目前仍然作为球墨铸铁管件生产的一种生产方式。
Clay sand is a type (core) sand with clay (clay) as binder. Clay sand modeling is still a production method of ductile iron pipe because of its low production cost.

(1)优点:生产成本低,生产灵活性大,生产率高,生产周期短。
 (1) advantages: low production cost, high production flexibility, high productivity and short production cycle.

(2)缺点:容易产生夹砂、结疤、鼠尾、气孔、砂眼、胀砂等铸造缺陷;不适合在中、大口径球铁管件生产;最佳口径≤DN300。
 (2) disadvantages: it is easy to produce casting defects such as sand clamping, scarring, rat tail, air hole, sand hole and sand swelling; It is not suitable for manufacturing medium and large caliber ductile iron pipe parts. The best caliber is less than or equal to DN300.

球墨铸铁管件常用生产工艺特点之覆膜砂铸造工艺
Ductile iron pipe fittings commonly used production process characteristics of the film - coated sand casting process

采用热塑性酚醛树脂加潜伏性固化剂(如乌洛托品)与润滑剂(如硬脂酸钙)通过一定的覆膜工艺配制成覆膜砂,覆膜砂受热时包覆在砂粒表面的树脂熔融,在乌洛托品分解出的亚甲基的作用下,熔融的树脂由线性结构迅速转变成不熔体的体型结构,从而使覆膜砂固化成形。
Using thermoplastic phenolic resin with latent curing agent (such as methenamine) and lubricant, such as calcium stearate) through a certain mixture of precoated sand coated technology, coated sand coated on the surface of the sand, resin melt when heated, in methenamine decomposition of methylene, under the action of molten resin by linear structure rapidly into not melt body structure, so that the solidification of precoated sand forming.

(1)优点:产品精度高且表面光洁;生产效率高;用人少;占地面积小。
 (1) advantages: high precision and smooth surface; High production efficiency; Less of choose and employ persons; It covers a small area.

(2)缺点:生产成本高;模具投资大;不适合在中、大口径球铁管件生产;最佳口径≤DN200。
 (2) disadvantages: high production cost; Large investment in molds; It is not suitable for manufacturing medium and large caliber ductile iron pipe parts. The best caliber is less than or equal to DN200.

球墨铸铁管件常用生产工艺特点之树脂砂铸造工艺
The resin sand casting process of ductile iron pipe fittings is commonly used

树脂砂铸造就是把原砂和树脂、固化剂混合均匀后放入砂箱、模样中造型制芯,合箱后进行浇注,是现在广泛采用的一种铸造方式,虽然尺寸精度比覆膜砂造型差一些,但其适合于多品种小批量的铸件,被管件企业广泛采用。
Resin sand casting is to evenly mix the sand and resin, curing agent into the sand box, shape modelling core making, casting box after on, is now widely used in a casting way, although the dimensional accuracy than some modelling of precoated sand is poor, but it is suitable for many varieties of small batch casting, are widely used in pipe fitting enterprise.

(1)优点:铸件尺寸精度高,外形轮廓清晰,铸件表面光洁,外观质量好,适应范围广,适合所有口径管件。
 (1) advantages: high dimensional precision of casting, clear outline, smooth surface of casting, good appearance quality, wide adaptability, suitable for all caliber pipe fittings.

(2)缺点:造型硬化反应需一定时间,其生产效率低;球铁管件表面因渗硫可能造成球化不良,浇注时有剌激性气味及一些有害气体发生;与黏土砂相比,成本较高。
 (2) disadvantages: the molding hardening reaction takes a certain time, and its production efficiency is low; The surface of the ductile iron pipe may be badly spheroidized due to the sulfur percolation. Compared with clay sand, the cost is higher.

球墨铸铁管件常用生产工艺特点之消失模铸造工艺
Ductile iron pipe parts commonly used in the production process characteristics of the disappearing mold casting process

消失模铸造是把涂有耐火材料涂层的泡沫塑料模样放入砂箱,模样四周用干砂充填,采用微震加负压紧实,在没有芯子的情况下浇注液态金属,在浇注和凝固过程中继续保持一定的负压,使泡沫塑料气化继而被金属取代形成铸件的一种新型铸造工艺方法。
Epc is coated with refractory coating of the foam plastic shape into the sand box, look around with dry sand filling, the micro vibration and negative pressure tight, in the absence of core pouring liquid metal, in the process of casting and solidification to keep certain negative pressure, make foam gasification and then replaced by metal casting method of a new type of casting process.

(1)优点:铸件精度高,壁厚均匀;设计灵活,通过泡沫塑料模片组合铸造出各种变径管件;机械加工余量小,甚至直接把法兰止水圈和法兰孔铸出。
 (1) advantages: high casting precision and even wall thickness; Flexible design, through the combination of foam plastic die casting a variety of variable diameter pipe pieces; The machining allowance is small, even directly casting the flange water ring and flange hole.

(2)缺点:并非所有的球体管件都适合消失模铸造工艺;管件表面容易出现皱皮,波纹状、滴瘤状、冷隔状、渣状、夹气夹杂状缺陷;工艺流程长;控制点多,技术要求高,管理难度大,管理人员、操作人员素质要求高;只适合中、大口径球铁管件生产。
 (2) disadvantages: not all spheroidal pipe fittings are suitable for the epc process; The surface of pipe fittings is prone to wrinkle, corrugation, droplet, cold septum, slag and air entrainment. Long process flow; There are many control points, high technical requirements, high management difficulties, and high quality requirements for managers and operators. It is only suitable for the production of medium and large caliber ductile iron pipe fittings.

球墨铸铁管件常用生产工艺特点之V法铸造工艺
Ductile iron pipe fittings commonly used production process characteristics of V - method casting process

真空密封造型(V法造型)与传统砂型铸造方法有很大的不同,是一种物理造型法。它将真空技术与砂型铸造结合,用不加水分和黏结剂的原砂造型,靠塑料薄膜将砂型的型腔面和背面密封起来,借助真空泵抽气产生负压,造成砂型内、外压差使型砂紧固成形,经下芯、合箱、浇注,待铸件凝固,解除负压或停止抽气,型砂便随之溃散而获得铸件。
The vacuum seal molding (V method modeling) is very different from the traditional sand casting method. It is a physical modeling method. It combines vacuum technology and sand mold casting, do not add water and caking agent the original sand molding, by the plastic film will sand mold cavity surface and sealed on the back, with the help of vacuum pump suction to produce negative pressure, caused by sand mould sand fastening with internal and external pressure forming, under the core, box, casting, casting solidification, remove or stop the smoke gas, negative pressure casting sand then to pieces.

(1)优点:管件表面光洁、轮廓清晰、尺寸准确;工艺流程短,生产成本低;金属利用率高,工艺出品率高;投资少;运行费用低;适应范围广;适合所有口径管件单件小批量。
 (1) advantages: smooth surface, clear outline and accurate size of pipe fitting; Short process and low production cost; High utilization rate of metal, high production rate of process; Less investment; Low operating cost; Wide range of adaptation; Suitable for small batch of all caliber pipe fittings.

(2)缺点:模具投资较大;造型效率不高。
 (2) disadvantages: large investment in molds; The modeling efficiency is not high.