The precision casting process of connecting flange is essential to ensure its high quality and good performance. The following are the relevant process points and quality control methods.
First, mold making is the key link. The precision of the mold directly affects the dimensional accuracy and surface quality of the connecting flange. High-precision processing equipment and advanced mold manufacturing technology are required to ensure that the dimensional tolerance of the mold cavity is controlled within a very small range, while ensuring the flatness and smoothness of the parting surface to avoid defects such as flash and burrs. For example, using a CNC machining center to make a mold can accurately mill out complex cavity contours, and through multiple measurements and calibrations, the dimensional error can be reduced to a minimum.
Secondly, in the selection and smelting of casting materials. According to the use requirements of the connecting flange, select suitable casting alloy materials, such as stainless steel, carbon steel, etc., and strictly control the purity and impurity content of the raw materials. During the smelting process, accurately control the smelting temperature, time and furnace atmosphere. Too high a temperature may cause alloy elements to burn out and affect the material properties; while too low a temperature may make the molten metal poorly fluid and unable to fill the cavity. For example, for the melting of stainless steel connecting flange, a vacuum induction furnace is required to melt at a precisely set temperature and vacuum degree to ensure uniform and pure alloy composition and improve the quality of castings.
In addition, the pouring process cannot be ignored. The pouring speed, pouring temperature and pouring method all need to be carefully designed. The appropriate pouring speed can make the molten metal fill the mold cavity smoothly, avoiding turbulence and the inclusion of gas or impurities; the pouring temperature should be determined according to the type of alloy and the structure of the casting, which can not only ensure the good fluidity of the molten metal, but also prevent the shrinkage cavity and shrinkage defects caused by excessive temperature. For example, the bottom pouring system is used to allow the molten metal to rise slowly from the bottom, which can effectively reduce the inclusion of gas and inclusions and improve the internal quality of the connecting flange.
Finally, quality control runs through the entire casting process. After the casting is formed, a comprehensive inspection should be carried out. This includes appearance inspection to check whether there are surface defects; dimensional measurement to verify whether it meets the design requirements; and internal quality inspection, such as using X-ray flaw detection, ultrasonic flaw detection and other methods to check whether there are internal defects such as pores, shrinkage cavities, cracks, etc. For unqualified products, it is necessary to analyze the reasons in time and take improvement measures, such as adjusting process parameters, optimizing mold design, etc., to ensure that the quality of connecting flange is stable and reliable and meets the strict requirements of industrial applications.
