型砂材質與擠壓成形工藝對砂型表面性能的影響

郭莉軍; 單忠德; 劉麗敏; 姜二彪

doi:10.13374/j.issn2095-9389.2020.01.15.002

型砂材質與擠壓成形工藝對砂型表面性能的影響

doi: 10.13374/j.issn2095-9389.2020.01.15.002

機械科學研究總院先進成形技術與裝備國家重點實驗室，北京 100044

基金項目: 國家杰出青年科學基金資助項目（51525503）；機械科學研究總院技術發展基金資助項目（311908Q9）

詳細信息

通訊作者:
E-mail：shanzd@cam.com.cn

中圖分類號: TG242.5
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出版歷程
- 收稿日期: 2020-01-15
- 刊出日期: 2021-02-26

Effect of sand-mold material and extrusion forming process on sand-mold surface properties

State Key Laboratory of Advanced Forming Technology and Equipment, China Academy of Machinery Science and Technology, Beijing 100044, China

More Information

Corresponding author: E-mail: shanzd@cam.com.cn

摘要

摘要: 以數字化柔性擠壓成形砂塊為研究對象，通過設計單因素試驗進行了砂型種類、粘結劑質量分數及擠壓壓力對型腔表面質量影響規律的研究，進而得出高精度樹脂砂型擠壓成形的最優參數組合。結果顯示：無模砂型外部與砂型內部的表面性能存在差異。不同砂型種類的砂型型腔表面性能不同，沙粒的角形系數對砂型型腔表面性能有較大影響。隨著砂型擠壓力的提高，砂粒之間的距離減小，砂粒并聯接觸方式增多，砂型在經過切削時，砂型表面產生裂紋的數量及延伸深度大幅減小，砂型型腔表面性能不斷提高。隨著樹脂質量分數的增大，砂粒的包覆厚度增大，從而砂粒的粘結橋增多，砂型強度增加，砂型切削時產生的裂紋數量減小，砂型型腔表面性能不斷提高。本文為真實獲得砂型表面質量提供了方法，有助于無模鑄造精密成形技術的推廣。
- 數字化柔性成形 /
- 無模成形 /
- 銑削工藝 /
- 樹脂砂 /
- 砂型表面性能
Abstract: Considering the digital flexible extrusion sand mold as the research object, the surface quality of sand mold was studied by designing a single-factor experiment, and then the optimal parameter for the high-precision flexible forming of sand mold was obtained. The results show that there are differences in surface properties between the outside and inside of the sand mold, and the different types of sand mold had different surface properties. The angle coefficient of sand has a great influence on the sand mold surface properties. With the increase in the extrusion force, the distance between sand grains decreases and the parallel connection mode of sand grains increases. When the sand mold was cut, the number and extension depth of cracks of the sand mold were greatly reduced; thus, the sand mold surface properties increased. With the increase in the resin content, the coating thickness of sand grains increases, the bonding bridge of sand grains increases, the sand mold strength increases, the number of cracks of sand mold decreases, and the surface properties of sand mold increase. In this paper, a new method to obtain the surface quality of sand mold is provided, which can help popularize the precision forming technology of pattern-less casting. The method of sand-mold near-net forming with digital flexible extrusion makes the extrusion unit array pack form the sand-mold cavity. Moreover, in the digital precision forming technology without pattern casting, by filling the mold with molding sand, holding pressure, and hardening, the sand-mold near-net forming is obtained as a preform. This technology saves a lot of molding sand and reduces the amount of cut molding sand in the process of the digital precision forming technology without pattern casting. As the preliminary process of the sand-mold digital precision forming without pattern casting, the technology of sand-mold near-net forming with digital flexible extrusion effectively shortens the development cycle of castings. The basic research on sand mold efficiently achieves high-quality and near-net forming of sand molds with digital flexible extrusion. The research improves the digital level, eco-friendliness, and efficiency level of pattern-less casting technology.
- digital flexible forming /
- pattern-less casting /
- milling process /
- resin sand /
- sand surface properties

HTML全文

圖 1 表面性能測試原理

Figure 1. Diagram of the surface property test

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圖 2 試樣加工

Figure 2. Sample processing

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圖 3 砂粒接觸模型

Figure 3. Sand contact model

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圖 4 砂粒質量與磨削次數的關系

Figure 4. Relationship between the sand quality and grinding time

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圖 5 砂粒形貌。（a）寶珠砂；（b）硅砂；（c）鉻鐵礦砂

Figure 5. Sand grain appearance: (a) ceramsite; (b) silica sand; (c) chromite sand

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圖 6 不同擠壓壓力、樹脂質量分數與砂型表面性能的關系. （a）樹脂質量分數1.6%; （b）樹脂質量分數2.0%；（c）樹脂質量分數2.4%；（d）樹脂質量分數2.8%；（e）樹脂質量分數3.2%

Figure 6. Relationship between the surface properties of sand mold and extrusion pressure under varying resin contents: (a) resin content 1.6%; (b) resin content 2.0%; (c) resin content 2.4%; (d) resin content 2.8%; (e) resin content 3.2%

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圖 7 不同樹脂質量分數與砂型表面性能的關系

Figure 7. Relationship between the surface properties of sand mold and resin content

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表 1 不同磨削次序型砂的表面性能

Table 1. Surface properties of sand under different grinding times

Times of grinding	Surface properties/g
First time	0.7075
Second time	0.4025
Third time	0.3675
Fourth time	0.3525
Fifth time	0.275

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表 2 不同種類型砂的表面性能

Table 2. Surface properties of different types of sand

Type of sand	Surface properties/g
Ceramsite	0.09
Silica sand	0.15
Chromite sand	0.28

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表 3 不同擠壓壓力下不同樹脂質量分數砂型的表面性能

Table 3. Surface properties of sand mold with different resin contents under different extrusion pressures

Different extrusion pressures /MPa	Surface properties of sand with different resin contents/g
Different extrusion pressures /MPa	1.6%	2.0%	2.4%	2.8%	3.2%
0	0.203	0.123	0.113	0.090	0.077
0.05	0.193	0.120	0.123	0.063	0.037
0.1	0.194	0.110	0.102	0.060	0.053
0.15	0.193	0.103	0.093	0.063	0.043
0.2	0.160	0.107	0.073	0.063	0.060

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表 4 不同樹脂質量分數砂型的表面性能

Table 4. Surface properties with different mass fraction of resin

Mass fraction of resin/%	Surface properties/g	Mass fraction of resin/%	Surface properties/g
1.6	0.708	2.4	0.235
1.8	0.65	2.6	0.247
2.0	0.62	2.8	0.25
2.2	0.51	3.0	0.23

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