Research And Application On Squeeze Casting Of Parts With Complex Inner Cavity

Due to core installation is difficult, squeeze casting technology is mainly use to cast simple structured parts at present. It can’t cast parts with complex inner cavity. Oxygen lance nozzle, as the representative of parts with complex inner cavity, the existing main molding process is sand casting, its quality is not high, and its service life is short Therefore, the dissertation puts forward the research idea of using the fusible metal core in squeeze casting technology, to cast complex inner cavity parts represented by oxygen lance nozzle; The dissertation respectively researches it from the design and feasibility studies of fusible metal core, oxygen lance nozzle squeeze casting technology and mold design, the production line configuration, and the numerical simulation research and validation.First, the dissertation demonstrates the advantages of using fusible metal core to mold complex inner cavity. Pure aluminum is selected as the material of fusible metal core to mold oxygen lance nozzle, and ductile iron lost foam casting coating as casting coating. The structure is separated structure, and manufacturing mode is casting and machining. It also determined the applying process. And then, the feasibility experimental study of the fusible metal core is carried out, and by using fusible metal core and sand mold casting oxygen lance nozzle is formed, which provides reference for the liquid die forging.Second, using oxygen lance nozzle of ΦD180x3as the specific research object, it provides design for its squeeze casting process design and mold design, including the optimization of oxygen lance nozzle workblank structure, choosing molding position with the disc underneath and the bottom pressured indirect squeeze casting as the way of squeeze casting, the design of process and the determination of process parameters; and design of the structure of the mold, molding parts, exhaust system and unloading system etc, and selection of mold materials.Third, according to the process design of oxygen lance nozzle squeeze casting, configure the YD800production line that can produce oxygen lance nozzle with diameter less than300mm. The vertical squeeze casting machine is selected, and design requirements of its main function, the action programming and main technical parameters are set. And the design requirements of main function, basic structure and main technical parameters are set for core smelting furnace used for smelting metal core, the aluminum smelting furnace used for keeping the smelting core warm so as to used in crafting metal core, drying oven used for drying and preheating metal core.The last, in order to further verify the feasibility of applying fusible metal core to squeeze casting, the researcher performs a squeeze casting simulation and analysis of the oxygen lance nozzle of0180x3. Finally draw the Conclusion that in this process, metal core can be smelt, but before that, the external copper liquid has formed a solidified shell, this solidified shell and metal core coating can separate the molten metal core from workblank, which will not become a waste product. This simulation result is verified by experiments.