特殊合金灰铸铁机架缩松问题分析及改进方法

Analysis and Improvement Method of Shrinkage Porosity of Special Alloy Gray Iron Frame

介绍了高铁牵引机车动力系统中柴油机机架铸件的结构及技术要求,对铸件加工后出现的倾向性缩松缺陷进行了大量分析,通过铸件温度场的模拟,重新布置内浇道位置,并采取相应的激冷措施,减小关键区域热节,有效降低了凝固收缩过程中的缩松风险;利用SPC统计过程控制方法监控关键参数波动趋势,调整浇注温度,控制Si、Cu和Cr元素含量,有效降低了缩松倾向。最后指出:在铸件整个生产过程中,应提前应用SPC统计过程控制方法监控各项关键参数的波动情况,出现异常点或异常趋势时可以立即采取措施,降低出现批量质量问题的概率,从而有效降低质量控制成本和质量损失。

The structure and technical requirements of diesel engine frame castings in the power system of high-speed railway traction locomotives were introduced.A large number of tendencies of shrinkage defects appearing after casting were analyzed.Through the simulation of casting temperature field,the position of inner runner was rearranged.And corresponding chilling measures were taken to reduce the thermal joints in key areas and effectively reduce the risk of shrinkage during solidification.The SPC statistical process control method was used to monitor the fluctuation trend of key parameters.The pouring temperature was adjusted,Si,Cu and Cr elements content were controlled.They effectively reducing the shrinkage tendency.Finally,it was pointed out that in the whole production process of castings,the SPC statistical process control method should be used to monitor the fluctuation of various key parameters in advance,and immediate measures should be taken when abnormal points or abnormal trends occur to reduce the probability of batch quality problems,thereby effectively reducing quality control costs and quality loss.