制造工程和技术Chapter 12 Metal Casting.ppt

Chapter 12 Metal Casting: Design, Materials and Economics 12章 金属铸件： 设计、材料和经济性 Content 12.1 Introduction 简介 12.2 Design Considerations 设计考虑 12.3 Casting Alloys 铸造合金 12.4 The Economics of Casting 铸件经济性 12.1 Introduction 12.2 Design Considerations These principles（原则） were established primarily through practical experience, but new analytical methods, process modeling, and computer-aided design and manufacturing techniques are now coming into wider use, improving productivity (生产力) and the quality of castings and resulting in significant cost savings. 12.2.1 Design for expendable-mold casting (一次性模铸造的设计) 1. Corners, angles and section thickness. Sharp corners (方角), angles (倒角) and fillets (肩角) should be avoided (Fig. 12.1), because they act as stress raisers and may cause cracking and tearing of the metals (as well as of the dies) during solidification. Fillet radii should be selected to reduce stress concentrations and to ensure proper liquid-metal flow during the pouring process. Fillet radii usually range from 3mm to 25mm, although smaller radii may be permissible (容许的) in small castings and in limited applications. On the other hand, if the fillet radii are too large, the volume of the materials in those regions is also large and, consequently, the rate of cooling is lower. 2. Flat areas (平面面积). Large flat areas (plain surfaces) should be avoided, because they may warp (翘曲) during cooling because of temperature gradients or develop poor surface finish. Flat surfaces can be broken up with ribs (肋条) and serrations. 3. Shrinkage. There should be allowances for shrinkage during solidification. Stagger: 错开排列, intersection geometry: 横截面几何形状. Pattern dimensions should also provide for shrinkage of the metal during solidification and cooling. Patternmaker’s shrinkage allowances: 模型制作的收缩允许率, usually range from about 10mm/m to 20mm/m. 4. Parting line. To be along a flat plane, rather than contoured, located at the corners or edges of castings. It is important for mold