09-3X中间体铸钢件铸造工艺优化

Casting process optimization of 09-3X steel-casting midbody

09-3X中间体为铁路捣固装置的重要组成部件,该铸钢件采用酯硬化水玻璃砂铸造工艺生产。原有的铸造工艺很难避免该铸件导柱孔内及其端面出现缩孔缩松缺陷,究其原因,主要是该产品结构复杂,导柱孔部位钢液补缩不畅所致。本文采用MAGMA模拟软件对铸件的凝固过程进行了模拟,并通过采取添加补贴、合理放置冒口以及调整冷铁位置等措施对原铸造工艺进行了优化。优化后的工艺方案,打通了原导柱孔部位的钢液补缩通道,并将原部位的缩孔缩松缺陷"引到"补缩通道中,消除了原部位的缩孔缩松缺陷。后期批量生产的铸件返修率降低至10%,大大降低了该铸钢件的生产成本。

The09-3X midbody is an important part of railway tamping device,which was produced by ester hardening water glass sand casting process.Due to the poor feeding effect which might be attributed to the complicated structure,our original casting process can hardly avoid the shrinkage and dispersed shrinkage defectsin the inward and end surface of oriented hole.Kinds of measures were used to optimize the casting process of09-3X midbody in this work,such as computer-assisted simulation of casting process by MAGMA software,reasonable setting of pad and riser,readjustment of chill position,etc.The optimized casting process dredged thefeeding channel in oriented hole,leading the shrinkage and dispersed shrinkage defects to the feeding channel,andas a result the casting quality was remarkably improved.In later batch production the repair rate decreased to10%,and then reduced cost greatly.