材料成形技术基础 （课程大作业）
专业： 机械制造及其自动化班级： 14级1班 姓名： 黄勇 学 号： 2014211118 指导教师： 马齐江 成绩：
2016年 6 月
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目录
一、零件介绍……………………………………………………………………1
二、造型材料选择················································································2 三、铸造工艺参数设计···········································································3
1.加工余量的选择···············································································4 2.铸件孔是否铸出的确定········································································5 3.起模斜度的确定···············································································6 4.铸造圆角的确定···············································································7 5. 铸造收缩率的确定···········································································8 6.木模的确定 ········································································9 四、工艺方案的初步确定……………………………………………………………………10
1．浇注位置的选择………………………………………………………………………………………10 2.分型面的选择…………………………………………………………………………………………11 五、型芯的设计…………………………………………………………………………………………………12 六、浇注系统的的设计··················································································13
1.浇口杯的设计··················································································14
2.内浇道截面设计··················································································14 3.横浇道···········································································。。。。…………….15 4.直浇道·········································································……………………16 七、冒口的设计·······················································································16 八、铸型装配图设计·····················································································18 九、设计体会……………………………………………………………………………………………………19 十、参考文献……………………………………………………………………………………………………19
一，零件介绍
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1、支座是指用以支承容器或设备的重量，并使其固定于一定位置的支承部件。还要承受操作时的振动与地震载荷。如室外的塔器还要承受风载荷。
2支座结构的铸造工艺性
零件结构的铸造工艺性是指零件的结构应符合铸造生产的要求，易于保证铸件品质，简化铸件工艺过程和降低成本。审查、分析应考虑如下几个方面： 1.铸件应有合适的壁厚，为了避免浇不到、冷隔等缺陷，铸件不应太薄。 2.铸件结构不应造成严重的收缩阻碍，注意薄壁过渡和圆角 铸件薄厚壁的相接拐弯等厚度的壁与壁的各种交接，都应采取逐渐过渡和转变的形式，并应使用较大的圆角相连接，避免因应力集中导致裂纹缺陷。
3.铸件内壁应薄于外壁 铸件的内壁和肋等，散热条件较差，应薄于外壁，以使内、外壁能均匀地冷却，减轻内应力和防止裂纹。 4.壁厚力求均匀，减少肥厚部分，防止形成热节。 5.利于补缩和实现顺序凝固。 6.防止铸件翘曲变形。
7.避免浇注位置上有水平的大平面结构。
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二、造型材料和铸造合金的选择
1. 造型和造芯材料
由于本次课程设计的铸件是中等批量生产，所以造型和造芯的方法应采用灵活多样，适应性强的手工造型。但它有生产率低，劳动强度大，铸件质量不易稳定的缺点。
造型方法可选用砂箱造型，其操作方便，无论是大、中、小型铸件，还是大量、成批和单件生产均可采用。型砂选择：铸钢用的型砂和泥心砂，其主要的组成部分是石英砂和耐火粘土。作为造型材料的沙子性质，由砂粒形状和大小，氧化硅的含量，以及沙子中存在的各种混合物来确定。该铸件型砂选用瘦沙（粘土含量2~10%）来代替石英砂。在湿模造型时，小型和中小型钢铸件泥心砂可以采用小颗粒的半肥沙（粘土含量10~20%）作为附加物加入石英砂中。加入的耐火粘土，其工艺试样的抗压强度应为0.5~0.6公斤/公斤2。耐火粘土应该是白色或者淡灰色的，不应有可被肉眼看出的混杂物，如砂子、矿石、石灰等。碎粘土所含水分不应超过2%。.（铸件材料是铸铁时，制造湿砂型的粘土砂所用粘土为膨润土，湿抗压强度一般为80-120kpa。含水量为4.5-5.5％，透气性为60-100，型砂配比70/140目占33，100/200目占17%， 红砂占50%。芯砂选择油砂或水玻璃砂。）
造芯的方法可采用芯盒造芯和刮板造芯，前者用于造各种形状、尺寸和批量的砂芯，后者用于造单件小批量生产，形状简单或回转体砂芯。 2. 铸造合金采用HT250
三、 铸造工艺参数设计
确定铸造工艺参数必须知道的零件尺寸，零件的详细尺寸如图2.1所示。
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图2.1 零件尺寸
1. 加工余量的选择
假定该槽轮为成批、大量生产，机器造型及壳型，则由《材料成型工艺基础》第三版P68 表4-2查得尺寸公差等级CT应为8~10级，选9级，加工余量等级MA选G。由课程设计题目知基本尺寸φ400mm，查《材料成型工艺基础》第三版P68 表4-3与尺寸公差配套使用的灰铸铁机械加工余量，并由确定加工余量中“顶面（相对于浇注位置）的加工余量等级应比底、侧面加工余量等级降一级选用”的规定查得，顶面加工余量应按照CT10级、MA-G级；底面、侧面的加工余量为CT9级、MA-G级。则顶面的加工余量取6.0mm,底面和侧面的加工余量取4.5mm。
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