潘永寧臺灣大學：機械工程學研究所王子威Wang, Zih-WeiZih-WeiWang2007-11-282018-06-282007-11-282018-06-282006http://ntur.lib.ntu.edu.tw//handle/246246/61226中文摘要 本研究針對消失模型鑄造法，選擇以球墨鑄鐵「壓圈」及「套筒」為載具，探討一些關鍵製程參數，如: 塗層材料、塗層厚度、模砂性質、模型材料性質、澆注溫度、流路系統設計等，對於鑄鐵件品質之影響，以建立消失模型鑄造法之量產技術。 根據本研究之實驗結果可獲致以下結論: (1) 消失模型鑄造法所使用之最佳保利龍模型密度應小於0.20 g/cm3 ，(2) 在造模填砂過程中需施以震動，且填滿後再持續震動一段時間，可提升模砂的堆積密度，並有效防止澆鑄時模砂發生崩塌現象，以得到理想的熔液充模， (3) 在鑄件頂部(凸緣)離進模口遠端處設計一溢流部(冒口)時，可顯著提升鑄件之外觀品質及消除內部(凸緣位置)縮孔， (4) 由消失模鑄件之尺寸量測結果得知，其固態收縮率約為1％。Abstract In this study, in order to establish the manufacturing technology of the lost foam casting process, the “seal ring” and “sleeve barrel” ductile iron castings were chosen as the carriers, and the effects of some selected processing parameters, such as pattern density, pattern coating, and gating system design, on the quality of the castings produced were studied. Based upon the results obtained, the following conclusions can be drawn: (1) The density of the foam pattern employed should remain in a suitable range, no higher than 0.02 g/cm3. (2) Vibration should be applied during the sand-filling process, and continue for a certain period of time after complete fill, in order to achieve better compaction and also reduce the propensity of mold collapse during casting. (3) For the “sleeve barrel” casting, designing an suitable over-flow (or a riser) at the upper, far side of the flange of the casting can serve as a reservoir for the thermal decomposed products of the foam pattern, which can effectively eliminate both the surface defects and internal shrinkage porosities, and hence, quality castings can be attained. (4) The percent solid contraction measured in the lost foam ductile iron castings is around 1%.目 錄 摘要..............................................i 目錄..............................................ii 表目錄............................................iv 圖目錄.............................................v 一、前言..........................................01 二、文獻回顧......................................02 2-1 消失模型鑄造法之製程..........................02 2-2 模型製作及性質................................02 2-3 流路系統設計..................................07 2-4 塗層..........................................09 2-5 震動造模......................................10 2-6 抽氣..........................................11 2-7 澆注溫度......................................12 2-8 消失模鑄件之尺寸精密度控制....................12 2-9 消失模型鑄造法之優點..........................13 2-10 消失模型鑄造法之限制.........................13 三、實驗目的與方法................................14 3-1實驗目的................................14 3-2 實驗流程...............................15 3-3 實驗方法......................................16 四、 實驗結果與討論...............................24 (I) 壓圈鑄件......................................24 (1) 實驗爐次A1及A2................................24 (2) 實驗爐次A3及A4................................27 (3) 實驗爐次A5及A6................................29 (4) 實驗爐次A7及A8................................31 (5)消失模壓圈鑄件之凝固收縮分析...................32 (6)消失模壓圈鑄件之顯微組織分析...................33 (7)消失模鑄件之固態收縮率分析.....................33 (II) 套筒鑄件...................................35 (1)實驗爐次B1及B2之實驗條件及實驗觀察.............35 (2)實驗爐次B3及B4之實驗條件及實驗觀察.............38 (3) 套筒鑄件金屬熔液流動分析......................40 (4)實驗爐次B5之實驗條件及實驗觀察.................42 (5)消失模套筒鑄件之凝固收縮分析...................43 (6)套筒鑄件之金相組織.............................47 (7)套筒鑄件之尺寸分析.............................48 五、結論..........................................52 參考文獻..........................................54 表目錄 表一.不同澆注溫度下，保利龍分解產物之種類及生成量....06 表二.本實驗所採用模砂之粒度分析......................17 表三.壓圈鑄件之實驗設計..............................19 表四.套筒鑄件之實驗設計..............................20 表五. 爐次A1及A2之實驗條件及實驗觀察.................24 表六. 爐次A3及A4之實驗條件及實驗觀察.................27 表七. 爐次A5及A6之實驗條件及實驗觀察.................29 表八. 爐次A7及A8之實驗條件及實驗觀察.................31 表九. 爐次B1及B2之實驗條件及實驗觀察.................35 表十. 爐次B1及B2之實驗條件及實驗觀察.................38 表十一. 爐次B5之實驗條件及實驗觀察...................42 表十二. 爐次B3、B4及B5實際量測結果...................49 圖目錄 圖1. 澆注鋁合金時保利龍之分解機構..............................................4 圖2. 澆注鋼鐵合金時保利龍之分解構..............................................5 圖3. 不同澆注溫度下保利龍分解之產物..............................................5 圖4. 實驗流程圖.................................15 圖5. 壓圈鑄件之形狀及尺寸.......................16 圖6. 套筒鑄件之形狀及尺寸.......................16 圖7. 保利龍壓圈模型.............................21 圖8. 保利龍套筒模型之發泡模具...................21 圖9. 本研究所使用之砂箱.........................22 圖10. 抽氣裝置..................................22 圖11. 双軸式震動裝置............................23 圖12. 雨淋式填砂裝置............................23 圖13. 爐次A1之澆注結果..........................25 圖14. 爐次A2之澆注結果..........................26 圖15. 金屬熔液外洩示意圖........................26 圖16. 爐次A3之澆注結果..........................28 圖17. 爐次A4之澆注結果..........................28 圖18. 鑄件之結砂缺陷............................30 圖19. 鑄件之氣孔缺陷............................30 圖20. 爐次A7及A8之鑄件外觀，(a) 爐次A7及(b) 爐次A8....31 圖21. 爐次A7之鑄件示意圖..............................32 圖22. 爐次A8之鑄件示意圖..............................32 圖23. 爐次A7及A8鑄件之切片檢查圖......................33 圖24. 爐次A8第12號試塊之缺陷圖........................33 圖25. 爐次A7之金相組織................................33 圖26. 爐次A8之金相組織................................33 圖27. 壓圈鑄件尺寸與模型尺寸之差異....................34 圖28. 爐次B1及B2之流路系統............................36 圖29. 爐次B1之澆注結果................................36 圖30. 爐次B1及B2之進模口截面積........................37 圖31. 爐次B2之澆注結果................................37 圖32. 爐次B2之豎澆道底部..............................37 圖33. 爐次B3之流路系統................................38 圖34. 爐次B4之流路系統................................38 圖35. 爐次B3之澆注結果................................39 圖36. 爐次B4之澆注結果................................40 圖37. 套筒鑄件金屬熔液流動分析........................41 圖38. 爐次B5之流路系統................................42 圖39. 爐次B5之澆注結果................................43 圖40. 爐次B4之切片位置................................43 圖41. 爐次B4切片檢查結果..............................44 圖42. 爐次B5之切片位置................................44 圖43. 爐次B5切片檢查結果..............................45 圖44. 縮孔位置示意圖..................................45 圖45. 溢流部(或冒口)之設計............................46 圖46. 改良後之流路系統設計............................46 圖47. 球墨鑄鐵之牛眼組織..............................47 圖48. 套筒鑄件量測尺寸位置............................48 圖49. 尺寸實際收縮率與預設收縮率之比較................501902827 bytesapplication/pdfen-US消失模型鑄造法砂心壓圈套筒保麗龍模型Lost foamseal ringsleeve barrelductile ironThermal decomposed productsthesishttp://ntur.lib.ntu.edu.tw/bitstream/246246/61226/1/ntu-95-R93522719-1.pdf