压缩机缸盖的泡模具设计及消失模铸造工艺探索.pdfVIP

摘 要 压缩机缸盖是大型车辆制动系统中的重要部件。美国Bendix 公司T-5011396 型 压缩机缸盖是种带有夹层的复杂腔体结构件。轮廓尺寸为200mm*130mm*70mm ， 平均壁厚 5mm，最薄处4mm ，材质为灰铸铁。目前生产该缸盖铸件的厂家都是采 用砂型组芯工艺生产，存在数个砂芯定位不准、内腔粘砂等缺陷，造成铸件成品率 不到70% 。为了攻克这些难关，湖北随通机械有限公司和华中科技大学合作探索用 消失模铸造工艺来生产该件。 作者利用UG 软件完成缸盖的三维设计、泡沫模样的分片设计和泡塑模具结构 设计。将聚苯乙烯颗粒注入模具腔内，在高温蒸汽和水冷依次作用下，得到尺寸稳 定的泡沫模片。为了提高模片之间的配合精度，设计出热粘结模具和冷粘结模具。 试验中采用冷粘结模具来定位模片，使粘结后的模样符合设计尺寸要求。把四片模 片组装成缸盖模样并与浇注系统连成整体，涂覆涂料后烘干埋箱造型，采用负压浇 注工艺得到铸件。 采用国产的涂料涂覆模样和浇注系统，烘干后采用国产砂粒来充填造型。既降 低生产成本，又满足消失模铸造工艺的要求。提出了改进内浇道的工艺方案，有效 地克服了砂粒烧结现象，铸件质量得到明显提高，生产的试验铸件得到厂家的初步 认可。 关键词: 消失模铸造 压缩机缸盖 模具设计 粘结工艺 浇注系统 I Abstract Compressor cylinder heads are very important parts in vehicle braking systems. The T-5011396 type compressor cylinder head of Bendix company is a complex cavum structure casting with interlayer. The outline size is about 200mm*130mm*70mm,with average 5mm wall thickness and 4mm least wall thickness, and the material is cast iron. At present the companies which produce the castings all adopt sand-moulding and sand core combination process with good casting proportion less than 70%, meanwhile there are many problems such as several sand cores locating not exact, sands adhesive to inside and so on. In order to overcome such problems, HuBei Suizhou mechanical limited company and Huazhong University of Science and Technology cooperate to try to produce the castings in lost foam casting process. Great CAD/CAM aided functions of UG were employed in casting three dimension design, foam pattern splitting design and lost foam mold structure design. The EPS beads were injected in models, enduring proper high temperature stream and subsequent water cooling, the pattern slices with stable sizes were produced. The four pattern slices and pouring system were glued together. The