Research On Casting Process Defeqt Of Synchronizer Ring Gear In Horizcrntal Continuous Casting

Horizontal continuous casting is used widely in our country, it has the advantage ofsaving investment, simple equipment, high efficiency, high yield advantages. Thecasting defect of horizontal continuous casting is very common, such as shrinkageporosity, shrinkage cavity, pore, surface crack, composition segregation and so on.These casing defects cause great harm, the surface and inner quality of castings areimpacted seriously. Not only delay production time and need to be solved quickly, butalso increasing production cost and reducing production efficiency.When using FA6502copper alloy in horizontal continuous casting, the shrinkageporosity is appeared on the inside surface of copper tube, and the graphite mould corewhich is in the crystallizer is easy to be snapped. To solve the problems, we do someresearches on adjusting alloy elements, improving the taper of the graphite mould,optimizing the casting parameters of horizontal continuous casting. The achievementsare as follows:(1)Through adjusting alloy elements and reducing the alloy element content of Mnand Fe, we get a new copper alloy FA6506. The casting shrinkage porosity defect isimproved dramatically when using the new copper alloy FA6505in horizontalcontinuous casting.(2)After adjusting the taper of the graphite mould core from0degree to1degree,the problem of the graphite mould core which is easy to be snapped is solved whenusing the new copper alloy FA6506in horizontal continuous casting.(3) Optimizing the casting parameters of horizontal continuous casting through thefive factors and four levels orthogonal test. When the casting speed is260kg/h, thecasting temperature is1120℃, the cooling water inlet temperature is20℃, the coolingwater pressure is0.5Mpa, the yield of the copper alloy tube is the highest, about89.8%.(4)After800℃60min solid solution treatment, the effect of solid solution ofFA6506copper alloy is the best. Along with the increase of aging time, the abrasionloss reduces firstly then increases. When the aging time is60min, the abrasion loss isthe least, the hardiness of the material is the largest and the wear resistance is the best.Along with the increase of aging temperature, the abrasion loss reduces firstly thenincreases. When the aging temperature is350℃, the abrasion loss is the least, thehardiness of the material is the largest and the wear resistance is the best. So, the besttreatment process is800℃60min solid solution treatment, then350℃60min agingtreatment.(5)Through using ANSYS software simulation analysis, we find that in certainpouring temperature range, the liquid hole depth increases along with the pouringtemperature. In certain cooling strength range, the liquid depth decreases along with theincrease of the cooling strength; in certain throwing speed rang, the liquid hole depthincreases along with the increase of the throwing speed.