4G6发动机FCD700凸轮轴的研制
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摘要
为了生产出满足日本标准ES-X51717 技术要求的FCD700 凸轮轴,本文主要从铸造工艺方案优化,合金化处理及喂线球化技术三方面进行了研究。
针对凸轮轴铸件易产生缩孔、缩松、气孔、夹渣及砂眼缺陷的实际情况,本文依据顺序凝固理论、均衡凝固理论和大孔出流理论,结合石墨化膨胀自补缩原理及凸轮轴的结构特点,采用封闭式浇注系统和垂直分型工艺,1 型2 件,分别设计出3 种铸造工艺方案,在DISA 造型线上进行对比试验。结果表明,依据均衡凝固理论和大孔出流理论,铸件倾斜5°度放置,只在第Ⅰ主轴径和第Ⅳ主轴径处设置冒口的工艺方案是合理、有效的,利用该方案生产的凸轮轴气孔、夹渣、砂眼缺陷平均降低6%,经X 光检测凸轮轴内部无缩孔、缩松等缺陷。
为了满足凸轮轴的技术要求,本文第二章主要进行了球化工艺和化学成分的优化试验,进行了铜合金化方案与铜-锡合金化方案对比试验。研究结果表明,选用钙含量为2.0%~3.5%的Z-1 球化剂,采用冲入法进行球化处理,炉内碳含量控制在3.60%~3.80%,铸件终硅量控制在2.0%~2.2%,铜含量控制在0.60%~0.80%,锡含量控制在0.06%~0.08%,采用废钢增碳工艺和瞬时孕育工艺可以生产出满足要求的FCD700 凸轮轴。铸件本体取样,球化率大于等于80%,珠光体含量大于等于95%,石墨尺寸最大小于等于80μm且平均小于等于40μm,渗碳体小于等于5%,抗拉强度大于等于700MPa,延伸率大于等于2%,硬度:HB229~302。
本文第三章进行了用喂线机向高温铁水内喂入高镁合金包芯线,对铁水进行球化处理的工艺试验。结果表明,使用WSQP30 牌号包芯线,出炉温度1490~1510℃,每包铁水重量控制在700~800kg,喂线速度控制在18 ~20m/min,喂线长度控制在12~17m 时,可以有效地把残余镁量控制在0.030%~0.050%,成功地用喂线技术生产出FCD700 牌号的凸轮轴。
In order to produce FCD700 camshaft which can fulfill the Japanese criterion of ES-X51717, this paper mainly studies three aspect: optimizing the processing programmer, alloying, feeding spheroidisation technique.
Considering the camshaft may easily produce draw, shrinkage porosity, pore, cinder inclusion, sand explosion, based on the order freezing theory, equilibrium freezing theory, macroporous efflux theory, then combining with graphitizing expand self-mend theory and the characterize of camshaft structure, by obturated irrigating system and vertical typing techniques, designing three casting technique methods with one type and two pieces, and compare them in the DISA moulding line. From the result we can induce that based on the equilibrium freezing theory and macroporous efflux theory, all the casts may lean 5°. Among all the casts there are two methods whose casting head is in the first and forth spindle track is reasonable and effective. Using the method we produced camshaft whose pore, cinder inclusion, sand explosion was below 6%, and draw and shrinkage porosity defects were not found by XRD.
In order to fulfill the technique requirements, in the second part of my paper we discuss the globurizing technology and chemical constitution optimal experiment. Then we also do a comparative experiment of copper alloying and tin-copper alloying. The result shows that when the content of calcium is 2.0%~3.5% in nodularizer, induce chocking method to globurize, the content of carbon is 3.60%~3.80% in furnace, the content of silicium is 2.0%~2.2% in the cast, the content of copper is 0.60%~0.80%, the content of tin is 0.06%~0.08%, by the technology of steel crap increase carbon and instantaneous inoculation method can fulfill the requirements of FCD700 camshaft. In our sample, globurizing rate is beyond 80%, the content of pearlyte is beyond 95%, the maximum size of graphite is less than 80μm and the average size is also less than
40μm, the content of cementite is less than 5%, the strength of extension is more than 700MPa, the extensibility is more tan 2%, hardness: HB229~302. In the third part of my paper we discuss the experiment, which uses a feed string machine to feed high magnesium alloy to molton iron. The result shows that using WSQP30 core-spun yarn, with the temperature of 1490~1510℃, the weight of every bag of molton iron is 700~800kg, the feeding velosity is 18 ~20m/min, and the lenghth of the core-spun yard is 12~17m, we can control the content of remained magnesium is 0.030%~0.050%, finally we can produce FCD700 camshaft successfully.
针对凸轮轴铸件易产生缩孔、缩松、气孔、夹渣及砂眼缺陷的实际情况,本文依据顺序凝固理论、均衡凝固理论和大孔出流理论,结合石墨化膨胀自补缩原理及凸轮轴的结构特点,采用封闭式浇注系统和垂直分型工艺,1 型2 件,分别设计出3 种铸造工艺方案,在DISA 造型线上进行对比试验。结果表明,依据均衡凝固理论和大孔出流理论,铸件倾斜5°度放置,只在第Ⅰ主轴径和第Ⅳ主轴径处设置冒口的工艺方案是合理、有效的,利用该方案生产的凸轮轴气孔、夹渣、砂眼缺陷平均降低6%,经X 光检测凸轮轴内部无缩孔、缩松等缺陷。
为了满足凸轮轴的技术要求,本文第二章主要进行了球化工艺和化学成分的优化试验,进行了铜合金化方案与铜-锡合金化方案对比试验。研究结果表明,选用钙含量为2.0%~3.5%的Z-1 球化剂,采用冲入法进行球化处理,炉内碳含量控制在3.60%~3.80%,铸件终硅量控制在2.0%~2.2%,铜含量控制在0.60%~0.80%,锡含量控制在0.06%~0.08%,采用废钢增碳工艺和瞬时孕育工艺可以生产出满足要求的FCD700 凸轮轴。铸件本体取样,球化率大于等于80%,珠光体含量大于等于95%,石墨尺寸最大小于等于80μm且平均小于等于40μm,渗碳体小于等于5%,抗拉强度大于等于700MPa,延伸率大于等于2%,硬度:HB229~302。
本文第三章进行了用喂线机向高温铁水内喂入高镁合金包芯线,对铁水进行球化处理的工艺试验。结果表明,使用WSQP30 牌号包芯线,出炉温度1490~1510℃,每包铁水重量控制在700~800kg,喂线速度控制在18 ~20m/min,喂线长度控制在12~17m 时,可以有效地把残余镁量控制在0.030%~0.050%,成功地用喂线技术生产出FCD700 牌号的凸轮轴。
In order to produce FCD700 camshaft which can fulfill the Japanese criterion of ES-X51717, this paper mainly studies three aspect: optimizing the processing programmer, alloying, feeding spheroidisation technique.
Considering the camshaft may easily produce draw, shrinkage porosity, pore, cinder inclusion, sand explosion, based on the order freezing theory, equilibrium freezing theory, macroporous efflux theory, then combining with graphitizing expand self-mend theory and the characterize of camshaft structure, by obturated irrigating system and vertical typing techniques, designing three casting technique methods with one type and two pieces, and compare them in the DISA moulding line. From the result we can induce that based on the equilibrium freezing theory and macroporous efflux theory, all the casts may lean 5°. Among all the casts there are two methods whose casting head is in the first and forth spindle track is reasonable and effective. Using the method we produced camshaft whose pore, cinder inclusion, sand explosion was below 6%, and draw and shrinkage porosity defects were not found by XRD.
In order to fulfill the technique requirements, in the second part of my paper we discuss the globurizing technology and chemical constitution optimal experiment. Then we also do a comparative experiment of copper alloying and tin-copper alloying. The result shows that when the content of calcium is 2.0%~3.5% in nodularizer, induce chocking method to globurize, the content of carbon is 3.60%~3.80% in furnace, the content of silicium is 2.0%~2.2% in the cast, the content of copper is 0.60%~0.80%, the content of tin is 0.06%~0.08%, by the technology of steel crap increase carbon and instantaneous inoculation method can fulfill the requirements of FCD700 camshaft. In our sample, globurizing rate is beyond 80%, the content of pearlyte is beyond 95%, the maximum size of graphite is less than 80μm and the average size is also less than
40μm, the content of cementite is less than 5%, the strength of extension is more than 700MPa, the extensibility is more tan 2%, hardness: HB229~302. In the third part of my paper we discuss the experiment, which uses a feed string machine to feed high magnesium alloy to molton iron. The result shows that using WSQP30 core-spun yarn, with the temperature of 1490~1510℃, the weight of every bag of molton iron is 700~800kg, the feeding velosity is 18 ~20m/min, and the lenghth of the core-spun yard is 12~17m, we can control the content of remained magnesium is 0.030%~0.050%, finally we can produce FCD700 camshaft successfully.
引文
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2 支德瑜. 铸铁在重要汽车零件上的应用实例以及与其他材质的比较. 现代铸铁, 2002, (2): 4~6
3 李平. 富康轿车凸轮轴国产化生产技术. 现代铸铁, 2002, (1): 33~35
4 杜军. 铸铁凸轮轴制造技术及国内外发展现状. 汽车工艺与材料, 1999, (3): 1~4
5 李树春. DA462 凸轮轴石墨析出黑线分析及解决措施. 新技术新材料, 2001, (9): 34~35
6 许世忠. 冷硬铸铁凸轮轴铸造技术与控制. 现代铸铁, 2003, (4): 44~45
7 张绪成. 激冷合金铸铁凸轮轴的铸造工艺. 铸造技术, 2000, (1): 30~31
8 郭戟荣. 铸态球铁的国内外研究及应用. 球铁, 1986, (2): 53~55
9 房贵如. 现代球墨铸铁的诞生、应用及技术发展趋势-20 世纪材料科学重大的技术进展之一. 现代铸铁, 2000, (1): 311~320
10 Dieter H. Mg-Wire Treatment of Ductile Iiron. Moder Casting, 1988, 78(2): 40~41
11 朱正宇. 喂线法生产蠕墨铸铁的研究. 现代铸铁, 2003, (3): 24~27
12 吴玉彬. 喂线技术在铸钢生产中的应用. 铸造, 1997, (10): 24~25
13 赵健康主编. 铸造合金及其熔炼. 机械工业出版社, 1986: 117~129
14 巫瑞智. 喂线技术在球铁应用中应注意的几个问题. 铸造技术, 2003,(6): 487~490
15 Ralph B. Magnesium Treatment Processes for S-G Iron Production. Foundry Trade Journal, 1987, 26(2): 119~121
16 张秉英. 喂线-钢包冶金的一项新技术. 钢铁, 1991, 26(7): 66~71
17 李玉庆. 合理设计浇注系统减少夹渣缺陷. 现代铸铁, 2003, (3): 21~24
18 薛祥. 液态金属静压力对缩孔缩松判据的影响. 铸造, 2003, (6): 426~428
19 李庆春主编. 铸件形成理论基础. 机械工业出版社, 1987: 222~248
20 曹文龙主编. 铸造工艺学. 机械工业出版社, 1989:193~276
21 魏兵. 铸件均衡凝固技术及其应用. 机械工业出版社, 1989: 15~18
22 陆文华主编. 铸铁及其熔炼. 机械工业出版社, 1987: 46~60, 108~113
23 周文彬. 球墨铸铁活塞环的铸造技术. 铸造, 2003, (8): 594~596
24 周惦武. EQ491 铸态珠光体球墨铸铁连杆的研究. 现代铸铁, 2002, (2): 19~21
25 严水娟. 铸态QT400-18 和QT800-2 铸件的生产. 现代铸铁, 2002, (4): 55~58
26 张树山. 铸态QT700-2 球墨铸铁的生产性工艺试验. 造型材料, 2003, (2): 39~40
27 梁义田主编. 合金元素在铸铁中的应用. 西安交通大学出版社, 1992:119~122, 161~163
28 刘进军. 高强度高韧性球铁曲轴的生产. 现代铸铁, 2002, (2): 47~48
29 袁征峰. 6BT 柴油发动机铸态排气歧管生产工艺. 铸造, 2002, (10): 634~635
30 Sinnos W. A Sandwish Process Using Pure Magnesium. The British Foundryman, 1980, (11): 22~24
31 黄汉云. 现场球化处理工艺及参数. 铸造技术, 2003, (1): 56~58
32 刘满平. 影响大断面球铁件石墨形态的因素. 铸造, 1998, (2): 40~42
33 戴塘顺. 确保大断面球墨铸铁件质量的措施. 现代铸铁, 2003, (3): 28~32
34 片冈义才. 添加锡对球墨铸铁的影响. 铸物, 1987, 39(2): 74~78
35 饶群章. 铬铸态珠光体球墨铸铁的研究. 球墨铸铁, 1992, (4): 3~6
36 Graham P S. Principles of Manufacturing Ductile Iron Gears. AFS Transactions, 2001, 46(6): 437~445
37 周克. 高硬度齿面铸态球墨铸铁大齿轮的研制和生产. 铸造, 2001, (7): 408~411
38 魏伯康. 用铜铬代钼生产大型球墨铸铁齿轮的试验研究. 现代铸铁, 1996, (2): 18~19
39 傅明喜. 防止大断面球铁石墨畸变的工艺措施. 热加工工艺, 2002, (4): 32~ 33
40 廖西平. 大断面高强度球铁曲轴的生产技术. 铸造, 2003, (8): 588~590
41 Campbell J. Castings Oxgord Cutter Worth Heineman. Second Edition, 2003, (3): 212~218
42 Hensen P N. How to Select and Use Criterion Functions in Solidification Simulation. AFS Transactions, 1993, (11): 443~445
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44 吴荷生. 用高镁合金包芯线生产球墨铸铁. 2001 中国铸造活动周论文集, 扬州, 2001: 127~129
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47 赵书城. 对球铁皮下气孔缺陷的认识. 现代铸铁, 2003, (2): 41~43
48 Hernandez B. Mechanisms of Pinhole Formation in Ductile Iron. AFS Transactions, 1979, 87(7): 335~348
49 Leiterman R. Pinhole and Slag Casting Defects in Ductile Iron Processing. AFS Transactions, 2004, (15): 225~228
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51 Kirst I. Use of Powder Wire in High –Strength Cast Iron Production. Liteinoe P-roizbvodstvo,1993,(10):11~12
52 柯捷良. 球墨铸铁活塞环铸件的生产. 现代铸铁,2003, (3): 31~33
53 柳安民. 球化质量炉前判断与控制. 现代铸铁,2002, (2): 46~48
2 支德瑜. 铸铁在重要汽车零件上的应用实例以及与其他材质的比较. 现代铸铁, 2002, (2): 4~6
3 李平. 富康轿车凸轮轴国产化生产技术. 现代铸铁, 2002, (1): 33~35
4 杜军. 铸铁凸轮轴制造技术及国内外发展现状. 汽车工艺与材料, 1999, (3): 1~4
5 李树春. DA462 凸轮轴石墨析出黑线分析及解决措施. 新技术新材料, 2001, (9): 34~35
6 许世忠. 冷硬铸铁凸轮轴铸造技术与控制. 现代铸铁, 2003, (4): 44~45
7 张绪成. 激冷合金铸铁凸轮轴的铸造工艺. 铸造技术, 2000, (1): 30~31
8 郭戟荣. 铸态球铁的国内外研究及应用. 球铁, 1986, (2): 53~55
9 房贵如. 现代球墨铸铁的诞生、应用及技术发展趋势-20 世纪材料科学重大的技术进展之一. 现代铸铁, 2000, (1): 311~320
10 Dieter H. Mg-Wire Treatment of Ductile Iiron. Moder Casting, 1988, 78(2): 40~41
11 朱正宇. 喂线法生产蠕墨铸铁的研究. 现代铸铁, 2003, (3): 24~27
12 吴玉彬. 喂线技术在铸钢生产中的应用. 铸造, 1997, (10): 24~25
13 赵健康主编. 铸造合金及其熔炼. 机械工业出版社, 1986: 117~129
14 巫瑞智. 喂线技术在球铁应用中应注意的几个问题. 铸造技术, 2003,(6): 487~490
15 Ralph B. Magnesium Treatment Processes for S-G Iron Production. Foundry Trade Journal, 1987, 26(2): 119~121
16 张秉英. 喂线-钢包冶金的一项新技术. 钢铁, 1991, 26(7): 66~71
17 李玉庆. 合理设计浇注系统减少夹渣缺陷. 现代铸铁, 2003, (3): 21~24
18 薛祥. 液态金属静压力对缩孔缩松判据的影响. 铸造, 2003, (6): 426~428
19 李庆春主编. 铸件形成理论基础. 机械工业出版社, 1987: 222~248
20 曹文龙主编. 铸造工艺学. 机械工业出版社, 1989:193~276
21 魏兵. 铸件均衡凝固技术及其应用. 机械工业出版社, 1989: 15~18
22 陆文华主编. 铸铁及其熔炼. 机械工业出版社, 1987: 46~60, 108~113
23 周文彬. 球墨铸铁活塞环的铸造技术. 铸造, 2003, (8): 594~596
24 周惦武. EQ491 铸态珠光体球墨铸铁连杆的研究. 现代铸铁, 2002, (2): 19~21
25 严水娟. 铸态QT400-18 和QT800-2 铸件的生产. 现代铸铁, 2002, (4): 55~58
26 张树山. 铸态QT700-2 球墨铸铁的生产性工艺试验. 造型材料, 2003, (2): 39~40
27 梁义田主编. 合金元素在铸铁中的应用. 西安交通大学出版社, 1992:119~122, 161~163
28 刘进军. 高强度高韧性球铁曲轴的生产. 现代铸铁, 2002, (2): 47~48
29 袁征峰. 6BT 柴油发动机铸态排气歧管生产工艺. 铸造, 2002, (10): 634~635
30 Sinnos W. A Sandwish Process Using Pure Magnesium. The British Foundryman, 1980, (11): 22~24
31 黄汉云. 现场球化处理工艺及参数. 铸造技术, 2003, (1): 56~58
32 刘满平. 影响大断面球铁件石墨形态的因素. 铸造, 1998, (2): 40~42
33 戴塘顺. 确保大断面球墨铸铁件质量的措施. 现代铸铁, 2003, (3): 28~32
34 片冈义才. 添加锡对球墨铸铁的影响. 铸物, 1987, 39(2): 74~78
35 饶群章. 铬铸态珠光体球墨铸铁的研究. 球墨铸铁, 1992, (4): 3~6
36 Graham P S. Principles of Manufacturing Ductile Iron Gears. AFS Transactions, 2001, 46(6): 437~445
37 周克. 高硬度齿面铸态球墨铸铁大齿轮的研制和生产. 铸造, 2001, (7): 408~411
38 魏伯康. 用铜铬代钼生产大型球墨铸铁齿轮的试验研究. 现代铸铁, 1996, (2): 18~19
39 傅明喜. 防止大断面球铁石墨畸变的工艺措施. 热加工工艺, 2002, (4): 32~ 33
40 廖西平. 大断面高强度球铁曲轴的生产技术. 铸造, 2003, (8): 588~590
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