JP2006224189A - Part prepared through sheet-making process for use in producing casting - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a part prepared through a sheet-making process for use in producing castings which can suppress the heat-shrinkage due to heat-decomposition, can form molten metal pouring systems corresponding to cavity-shapes in various dies, and has an excellent handleability. <P>SOLUTION: The part comprises an organic fiber, an inorganic fiber, and a binder. The contents of the organic fiber, the inorganic fiber, and the binder are preferably 10 to 70 pts.wt., 1 to 80 pts.wt., and 10 to 85 pts.wt., respectively. The binder is preferably an organic binder. The organic fiber is preferably pulp fiber. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a papermaking part for producing a casting and a method for producing a casting using the same.

  In casting production, generally, a casting mold is used to form a mold having a cavity (a core if necessary), and a receiving port, a gate, a runner and a weir (hereinafter referred to as “note”). (Also referred to as a hot water system) is formed so as to communicate with the cavity, and further, venting, hot water, and frying are formed. Such pouring systems, degassing, hot water, and frying are usually formed integrally with casting molds with casting sand, or the pouring system is made of pouring components made of refractory materials such as ceramics and bricks. Formed.

  When the casting mold and the pouring system are integrally formed of casting sand, it is difficult to arrange the pouring system in a three-dimensionally complex manner, and it is necessary to prevent sand from entering the molten metal. . On the other hand, in the case of using the pouring system component made of the refractory material, it is necessary to prevent a temperature drop due to heat loss of the molten metal, and setting work such as winding the refractory materials with a tape and adding them is troublesome. In addition, after casting, the refractory material is damaged due to thermal shock or the like, and a large amount of industrial waste (gara) is generated. When the refractory material is adjusted to a predetermined length, it must be cut with a high-speed cutter such as a diamond cutter, and the handling of the refractory material is generally troublesome.

  As a technique for solving such a problem, for example, a technique described in Patent Document 1 below is known. In this technique, a heat insulating material obtained by molding a slurry in which an organic or inorganic fiber and an organic or inorganic binder are mixed in a mold is used for a pouring system or the like.

  However, since the heat insulating material is formed by mixing an organic or inorganic fiber and an organic or inorganic binder, the heat insulating material generated when molten metal is supplied when the organic fiber and the organic binder are combined. There was a problem that the molten metal leaked from the pouring system, etc. due to the thermal decomposition of the molten metal. In addition, when the inorganic fiber and the inorganic binder are combined, it is difficult to mold the heat insulating material into a three-dimensional form such as a hollow or a form having a fitting structure, and the like corresponding to various cavity shapes. A hot water system or the like could not be formed.

  Furthermore, a technique using a core manufactured by adding inorganic powder and / or inorganic fiber to cellulose fiber is also known (see, for example, Patent Document 2 below). Since the core contains the inorganic powder or the inorganic fiber, shrinkage of the core during drying is suppressed during the manufacture of the core. Further, by using the core, the amount of gas and tar-like polymer compound generated from the cellulose fiber during casting is suppressed, casting defects are reduced, and workability during casting is improved.

  However, the core obtained by this technique has the above-mentioned advantages but does not contain a binder. Therefore, this core cannot be applied to the formation of a pouring system or the like corresponding to various cavity shapes including a hollow runner or the like.

Japanese Utility Model Publication No. 1-60742 Japanese Patent Laid-Open No. 9-253792

  Accordingly, an object of the present invention is to provide a papermaking part for producing a casting, which can suppress heat shrinkage due to thermal decomposition, can form a pouring system corresponding to various cavity shapes, etc., and is excellent in handleability. Another object of the present invention is to provide a casting manufacturing method using

  This invention achieves the said objective by providing the papermaking part for casting manufacture containing an organic fiber, an inorganic fiber, and a binder.

  The present invention also relates to a method for producing a casting using a papermaking part for casting production containing organic fibers, inorganic fibers and a binder, wherein the papermaking part for casting production is disposed in foundry sand. It is to provide.

  Further, the present invention is a method for producing a papermaking part for casting production according to the present invention, wherein a process of papermaking a molded body from a raw material slurry containing the organic fibers and the inorganic fibers, and The manufacturing method of the papermaking part for casting manufacture which comprises the process of including a binder is provided.

  According to the present invention, there is provided a papermaking part for casting production that is capable of forming a pouring system corresponding to the cavity shape of various molds and that is excellent in handleability and that can suppress thermal shrinkage due to thermal decomposition. A method for producing the casting used is provided.

  Hereinafter, the present invention will be described based on preferred embodiments thereof.

  The papermaking part for producing a casting of the present invention contains organic fibers, inorganic fibers, and a binder.

The organic fiber has a skeleton in a state before being used for casting in a papermaking part for casting production, and a part or all of it is burned by the heat of the molten metal at the time of casting, and voids are formed inside the papermaking part after casting production. Form.
Examples of the organic fibers include paper fibers, fibrillated synthetic fibers, regenerated fibers (for example, rayon fibers) and the like, and these are used alone or in combination of two or more. Among these, paper fiber is preferable. The reason for this is that paper fibers are easily available and stable, the manufacturing cost of the molded body is reduced, the paper body can be formed into various forms by papermaking, and the dehydrated and dried molded body has sufficient strength. .

  In addition to wood pulp, cotton pulp, linter pulp, bamboo straw and other non-wood pulp can be used for the paper fiber. Virgin pulp or waste paper pulp (collected product) can be used alone or in admixture of two or more. Waste paper pulp is particularly preferred from the standpoints of availability, stability, environmental protection, and reduction in production costs.

  The average fiber length of the organic fiber is preferably 0.8 to 2.0 mm, and more preferably 0.9 to 1.8 mm. If the average fiber length of the organic fibers is too short, the surface of the molded body may be cracked, or mechanical properties such as impact strength may be inferior. It may get worse.

  10-70 weight part is preferable and, as for content of the said organic fiber, 20-60 weight part is more preferable. In addition, in this specification, a weight part means the value with respect to a total of 100 weight part of an organic fiber, an inorganic fiber, and a binder. If the organic fiber content is too small, the organic fiber that forms the skeleton of the papermaking part will be insufficient, resulting in poor formability of the papermaking part, and the strength of the papermaking part after dehydration or drying may be insufficient. A large amount of combustion gas is generated during pouring, and blowing back occurs from the pouring gate, or it is lifted (a thin rod-shaped gap provided at the top of the mold, where the molten metal rises to the top of the mold after filling the mold. ) May cause a severe flame, and depending on the fiber used, the manufacturing cost may be high.

  The inorganic fiber mainly forms a skeleton in a state before being used for casting in a papermaking part for casting production, and maintains its shape without being burned by the heat of molten metal during casting. In particular, when an organic binder, which will be described later, is used as the binder, the inorganic fibers can suppress thermal shrinkage caused by thermal decomposition of the organic binder due to the heat of the molten metal.

  Examples of the inorganic fibers include carbon fiber, artificial mineral fibers such as rock wool, ceramic fibers, and natural mineral fibers, which are used alone or in combination. Among these, it is preferable to use a carbon fiber having high strength even at a high temperature from the viewpoint of suppressing the heat shrinkage. Moreover, it is preferable to use rock wool from the viewpoint of reducing manufacturing costs.

  The average fiber length of the inorganic fibers is preferably 0.2 to 10 mm, and more preferably 0.5 to 8 mm. If the average fiber length of the inorganic fibers is too short, drainage may be reduced and dewatering may occur during the manufacture of the papermaking part. In addition, papermaking properties may be reduced during the manufacture of thick papermaking parts (particularly hollow three-dimensional shapes such as bottles). On the other hand, if the average fiber length of the inorganic fibers is too long, there is a possibility that a paper-making part having a uniform thickness may not be obtained, which may make it difficult to produce a hollow paper-making part.

  The content of the inorganic fiber is preferably 1 to 80 parts by weight, and more preferably 4 to 40 parts by weight. If the inorganic fiber content is too low, the strength of the paper-made part produced using an organic binder, especially when cast, is reduced, and the paper-making part shrinks and cracks due to carbonization of the binder. There is a risk that a phenomenon in which the wall surface of the component is separated into an inner layer and an outer layer). Furthermore, a defective product may be manufactured by mixing a part of the papermaking part or casting sand into the product (casting). If the content of the inorganic fiber is too large, the formability of the papermaking part particularly in the papermaking process or the dewatering process is lowered, and the part cost may be high depending on the fiber used.

  The ratio of the inorganic fiber to the organic fiber (inorganic fiber content / organic fiber content) is a weight ratio. For example, when the inorganic fiber is a carbon fiber, 0.15 to 50 is preferable, and 0.25 to 30 is more preferable. preferable. When inorganic fiber is rock wool, 10-90 are preferable and 20-80 are more preferable. If there are too many inorganic fibers, the formability of papermaking parts in papermaking and dehydration molding will be reduced, and the strength of the papermaking parts after dehydration will be insufficient, and the papermaking parts may break when taken out from the papermaking mold. When there are too few inorganic fibers, a papermaking part may shrink | contract due to the thermal decomposition of an organic fiber and the below-mentioned organic binder.

  Examples of the binder include an organic binder and an inorganic binder as described later. The organic binder and the inorganic binder can be used alone or in combination.

The organic binder may be added to the raw material slurry of the papermaking part or may be impregnated in the manufactured papermaking part. When added to the raw material slurry, when the papermaking part is dried, the binder binds the organic fiber and the inorganic fiber to obtain a papermaking part with high strength. When the papermaking part is impregnated, when the papermaking part is dried and the binder is hardened, the binder is carbonized by the heat of the molten metal at the time of casting, and the strength of the papermaking part is maintained at the time of casting.
As said organic binder, thermosetting resins, such as a phenol resin, an epoxy resin, and a furan resin, are mentioned. Among these, it is particularly preferable to use a phenol resin from the viewpoints that the generation of combustible gas is small, there is a combustion suppressing effect, and the residual carbon ratio after pyrolysis (carbonization) is high. As the phenol resin, a novolak phenol resin that requires a curing agent as described below, or a resol type phenol resin that does not require a curing agent is used. The said organic binder is used individually or in mixture of 2 or more types.

The inorganic binder is one that binds the organic fiber and the inorganic fiber when the paper-made part is dry-molded before casting, the one that remains at the time of casting and has the effect of suppressing the generation of combustion gas and flame, There are those that melt by heat and exhibit the ability as a binder, and those that have the effect of preventing so-called carburizing during casting.
Examples of the inorganic binder include compounds containing SiO ₂ as a main component such as colloidal silica, obsidian, nacre, ethyl silicate, and water glass. Among these, it is particularly preferable to use colloidal silica from the standpoints that it can be used alone and is easy to apply. In view of the points that can be added to the raw slurry and the prevention of carburization, it is preferable to use obsidian. The said inorganic binder is used individually or in mixture of 2 or more types.

  The content of the binder (solid content) is preferably 10 to 85 parts by weight, and more preferably 20 to 80 parts by weight. If the binder content is too small, pinholes may be generated in the papermaking part and the compression strength of the papermaking part may be reduced. When the organic binder is used, the strength of the papermaking part may be insufficient when pouring, and casting sand may be mixed into the product. If the binder content is too high, the papermaking part may stick to the mold during dry forming after papermaking, which may hinder separation of the papermaking part from the mold.

When a binder other than obsidian is used, the content of the binder is preferably 10 to 70 parts by weight, and more preferably 20 to 50 parts by weight.
When obsidian is used as the binder, it is preferable that at least 20 parts by weight of obsidian is included in the total binder. Only obsidian can be used as the binder.

  In the production of the papermaking part for casting production according to the present invention, a curing agent is required when a novolac phenol resin is used. Since the curing agent is easily soluble in water, it is preferably applied to the surface of the papermaking part after dehydration. It is preferable to use hexamethylenetetramine or the like as the curing agent.

Further, as the binder, two or more types having different melting points or thermal decomposition temperatures can be used in combination. In particular, the low melting point binder and the high melting point binder are used in order to maintain the shape of the papermaking part when it is exposed to high temperature during casting from before casting at normal temperature, and to prevent carburization during casting. Is preferred. In this case, examples of the low melting point binder include clay, water glass, obsidian, and the like, and examples of the high melting point binder include colloidal silica, wollastonite, mullite, and Al ₂ O ₃ . Examples of combinations of binders having different melting points or thermal decomposition temperatures include a combination of obsidian and a phenol resin. Obsidian has a melting point of 1200 ° C. to 1300 ° C., and a thermal decomposition temperature of phenol resin is about 500 ° C. (The result of weight loss measurement in nitrogen gas (DTA) shows that 40 wt% of phenol resin is decomposed, about 50% decomposes at about 500 ° C).

In addition to the organic fiber, the inorganic fiber, and the binder, a paper strength reinforcing material may be added to the papermaking part for casting production according to the present invention. The paper strength reinforcing material has an effect of preventing swelling of the intermediate molded body when the intermediate molded body of the papermaking part is impregnated with a binder (described later).
The amount of the paper strength reinforcing material used is preferably 1 to 20%, particularly preferably 2 to 10% of the total weight of the fibers. If there is too little paper strength reinforcing agent, the above-mentioned swelling prevention may be insufficient, or the added powder may not be fixed to the fiber. It may become easy to stick.
Examples of the paper strength reinforcing material include polyvinyl alcohol, carboxymethyl cellulose (CMC), and polyamidoamine epichlorohydrin resin.

  Components such as a flocculant and a colorant can be further added to the papermaking part for producing a casting of the present invention.

  The thickness of the papermaking part for producing castings can be set according to the purpose of use, etc., but the thickness of at least the portion in contact with the molten metal is preferably 0.2 to 5 mm, more preferably 0.4 to 3 mm. If it is too thin, the strength of the papermaking part will be insufficient, and it may be difficult to maintain the shape and function desired for the papermaking part under the pressure of casting sand. If it is too thick, the air permeability is impaired, the raw material cost is increased, the molding time is increased, and the production cost may be increased.

  The papermaking part for producing a casting is preferably 10N or more, more preferably 30N or more, in the state before being used for casting. If the compressive strength is too low, it may be deformed by being pressed by foundry sand, and the function as a papermaking part may be impaired.

  When the papermaking part for casting production is produced using a raw material slurry containing water, the weight water content before use of the papermaking part for casting production (before being used for casting) is preferably 10% or less, % Or less is more preferable. The reason is that the lower the water content, the lower the amount of gas generated due to the thermal decomposition (carbonization) of the organic binder during casting.

  The specific gravity before use of the papermaking part for casting production is preferably 1.0 or less, and more preferably 0.8 or less. The reason for this is that when the specific gravity is small, the weight becomes light, and the handling and processing of the papermaking part become easy.

Next, based on the example of the manufacturing method of the papermaking components for casting manufacture with a hollow inside, the manufacturing method of the papermaking components for casting manufacture of this invention is demonstrated.
First, a raw slurry containing the organic fiber, the inorganic fiber, and the binder in the predetermined ratio is prepared. The raw material slurry is prepared by dispersing the fibers and the binder in a predetermined dispersion medium. The binder may be impregnated without adding the binder.

  Examples of the dispersion medium include water, white water, and solvents such as ethanol and methanol. Water is particularly preferable from the viewpoints of stability of papermaking and dehydration molding, stability of the quality of the molded body, cost, and ease of handling.

  The total ratio of the fibers to the dispersion medium in the raw slurry is preferably 0.1 to 3% by weight, and more preferably 0.5 to 2% by weight. If the total proportion of the fibers in the raw material slurry is too large, unevenness in the thickness of the molded body tends to occur, and in the case of a hollow product, the surface property of the inner surface may be deteriorated. If the amount is too small, local thin portions may occur in the molded body.

  If necessary, additives such as the paper strength reinforcing material, the flocculant, and the preservative can be added to the raw material slurry.

Next, an intermediate formed body of a papermaking part for casting production is made using the raw material slurry.
In the paper making process of the intermediate formed body, for example, the cavity for the paper forming / dehydration forming in which a cavity having a shape corresponding to the outer shape of the intermediate formed body is formed by abutting a pair of split molds formed by two pieces. Use a mold. Then, a predetermined amount of raw material slurry is injected under pressure from the upper opening of the mold into the cavity. Thereby, the inside of the cavity is pressurized to a predetermined pressure. Each split mold is provided with a plurality of communication holes that communicate the outside with the cavity, and the inner surface of each split mold is covered with a net having a mesh of a predetermined size. For example, a pressure feed pump is used for the pressure injection of the raw slurry. The pressure for pressure injection of the raw material slurry is preferably 0.01 to 5 MPa, more preferably 0.01 to 3 MPa.

  As described above, since the inside of the cavity is pressurized to a predetermined pressure, the dispersion medium in the raw material slurry is discharged out of the mold from the communication hole. On the other hand, the solid content in the raw material slurry is deposited on the net covering the cavity, and a fiber laminate is uniformly formed on the net. In the fiber laminate obtained in this way, organic fibers and inorganic fibers are intricately entangled and a binder is interposed between them, so that even if it has a complicated shape, it is highly retained even after dry molding. Formability is obtained. Further, since the inside of the cavity is pressurized to a predetermined pressure, even when a hollow intermediate molded body is formed, the raw material slurry flows in the cavity and the raw material slurry is stirred. Therefore, the slurry concentration in the cavity is made uniform, and the fiber laminate is uniformly deposited on the net.

After the fiber laminate having a predetermined thickness is formed, the pressure injection of the raw material slurry is stopped, and air is injected into the cavity to pressurize and dehydrate the fiber laminate. Thereafter, the press-fitting of air is stopped, the inside of the cavity is sucked through the communication hole, and an elastic, expandable and hollow core (elastic core) is inserted into the cavity.
The core is made of urethane, fluorine-based rubber, silicone-based rubber, or elastomer that has excellent tensile strength, impact resilience, stretchability, and the like.

  Next, a pressurized fluid is supplied into the core inserted into the cavity to expand the core, and the fiber laminate is pressed against the inner surface of the cavity by the expanded core. Thereby, the fiber laminate is pressed against the inner surface of the cavity, the shape of the inner surface of the cavity is transferred to the outer surface of the fiber laminate, and the dehydration of the fiber laminate proceeds.

  As the pressurized fluid used for expanding the core, for example, compressed air (heated air), oil (heated oil), and other various liquids are used. Further, the supply pressure of the pressurized fluid is preferably 0.01 to 5 MPa in view of the production efficiency of the molded body, and preferably 0.1 to 3 MPa in terms of particularly efficient production. If the pressure is less than 0.01 MPa, the drying efficiency of the fiber laminate may be reduced, and the surface property and transferability may be insufficient. If the pressure exceeds 5 MPa, the effect is not greatly improved, and the apparatus is enlarged. .

  Thus, since the fiber laminate is pressed against the inner surface of the cavity from the inside, even if the shape of the inner surface of the cavity is complicated, the inner surface shape is accurately transferred to the outer surface of the fiber laminate. Moreover, even if the molded body to be manufactured has a complicated shape, the bonding step of each part is not necessary, and therefore the finally obtained component does not have joints and thick portions due to bonding.

  When the inner surface shape of the cavity is sufficiently transferred to the outer surface of the fiber laminate and the fiber laminate can be dehydrated to a predetermined moisture content, the pressurized fluid in the core is drained, and the core is returned to its original size. It will automatically shrink. Then, the contracted core is taken out from the cavity, and the mold is opened to take out a wet fiber laminate having a predetermined moisture content. The pressing and dehydration of the fiber laminate using the above-described core can be omitted as necessary, and the fiber laminate can be dehydrated and molded only by pressurization and dehydration by press-fitting air into the cavity.

  The dehydrated fiber laminate is then transferred to a heating / drying process.

  In the heating / drying step, a dry molding die in which a cavity having a shape corresponding to the outer shape of the intermediate molded body is formed is used. Then, the mold is heated to a predetermined temperature, and the wet fiber laminate obtained by dehydration molding is loaded into the mold.

  Next, a core similar to the core used in the paper making process is inserted into the fiber laminate, a pressurized fluid is supplied into the core to expand the core, and the expanded core The fiber laminate is pressed against the inner surface of the cavity. It is preferable to use a core whose surface is modified with a fluorine resin, a silicone resin or the like. The supply pressure of the pressurized fluid is preferably the same pressure as in the dehydration step. Under this condition, the fiber laminate is heated and dried to dry-mold the intermediate molded body.

  The heating temperature (mold temperature) of the mold for dry molding is preferably 180 to 250 ° C, more preferably 200 to 240 ° C from the viewpoint of surface properties and drying time. If the heating temperature is too high, the intermediate molded body may be burnt and its surface properties may be deteriorated. If it is too low, it takes time to dry the intermediate molded body.

  When the fiber laminate is sufficiently dried, the pressurized fluid in the core is drawn out, the core is shrunk and taken out from the fiber laminate. And the said metal mold | die is opened and the said intermediate molded object is taken out.

The obtained intermediate molded body can be further impregnated partially or entirely with a binder, if necessary.
Examples of the binder impregnated in the intermediate molded body include resol type phenol resin, colloidal silica, ethyl silicate, water glass and the like.
When the intermediate molded body is impregnated with a binder and is not included in the raw material slurry, the raw material slurry and white water can be easily treated.
After impregnating the binder, the intermediate molded body is heated and dried at a predetermined temperature, and the binder is thermally cured to complete the production.

  Since the papermaking part thus obtained is pressed by the elastic core, the smoothness of the inner surface and the outer surface is high. For this reason, molding accuracy is also high, and a highly accurate papermaking part can be obtained even when it has a fitting part and a screw part. Therefore, the papermaking parts connected by these fitting parts and screw parts can surely suppress the hot water leakage, and the hot water flows smoothly through the parts. Moreover, since the heat shrinkage rate of the papermaking part at the time of casting is less than 5%, it is possible to reliably prevent hot water leakage due to cracking or deformation of the papermaking part.

  The papermaking part for producing a casting according to the present invention can be applied to a runner for a gate such as the embodiment shown in FIG. In FIG. 1, the code | symbol 1 has shown the runner.

As shown in FIG. 1, the runner 1 has two cylindrical members 11 and 12 connected by fitting. The opening 12a above the cylindrical member 12 has a diameter increased by a predetermined length, and the inner surface of the tip 12b is provided with a taper (reverse taper) that gradually increases in diameter upward. Therefore, it becomes easy to fit the lower end opening of the member to be connected (cylindrical member 11 in FIG. 1) and can be reliably fitted to a predetermined depth.
The ratio of the diameter expansion of the opening 12a of the cylindrical member 12 is set so that the inner surfaces of the cylindrical members 11 and 12 are flush with each other. The tubular member 12 is bent horizontally at the lower side, and a runner for runners (see FIG. 3) 3 is connected to the horizontal opening 12c.

  When the runner 1 is manufactured, as shown in FIG. 2A, the cylindrical member 11 is integrally formed at the upper end portion of the cylindrical member 12 in an inverted state, and the horizontal opening 12c is formed. It is preferable that the unopened intermediate molded body 10 is manufactured by the manufacturing method.

  As shown in FIG. 2B, the obtained intermediate molded body 10 is cut at predetermined cutting locations (A and B in FIG. 2A), and these are fitted as shown in FIG. A sprue runner (a papermaking part for casting production) having a bent portion is connected (see FIG. 3).

  Next, the casting manufacturing method of the present invention will be described based on the casting manufacturing method using the gate runner 1.

  First, as shown in FIG. 3, the pouring runner 1, the pouring runners 2, 3, and 4, the venting runner 5, and the hot water (top and side) runner 6 7, a papermaking part for casting production comprising a runner 8 for lifting and a mold 9 having a cavity (not shown) is arranged at a predetermined position.

  Then, these papermaking parts for producing castings are embedded in foundry sand, and molten metal having a predetermined composition is guided into the cavity of the mold 9 through the pouring system. At this time, when the organic binder is used as the binder, the papermaking part of the present invention is thermally decomposed and carbonized by the heat of the molten metal, but has sufficient strength. Can be inherited. Moreover, since the thermal contraction due to the thermal decomposition is suppressed by the inorganic fiber, each runner is hardly cracked or the papermaking part is hardly washed away, and the molten metal is not mixed with foundry sand or the like. . In addition, since the organic fibers are thermally decomposed, it is easy to remove the papermaking parts after dismantling the mold and taking out the cast product.

  As the foundry sand, sand conventionally used for producing this kind of foundry can be used without any particular limitation.

  After the casting is finished, it is cooled to a predetermined temperature to remove the foundry sand, and the cast product is exposed by blasting. Further, unnecessary portions such as the carbonized papermaking parts for casting production, such as a pouring system, are removed. Then, post-processing such as trimming is performed as necessary to complete the casting production.

As described above, in the papermaking part for casting production according to the present invention, the organic fibers are burned by the heat of the molten metal to form voids therein, the strength is maintained by the inorganic fibers and the binder, and the mold is disassembled. It can be easily separated or removed from the foundry sand by blasting or the like. In other words, the papermaking part for casting production according to the present invention uses organic fibers, inorganic fibers and a binder, so that the strength is maintained during molding or pouring of the mold, and the strength decreases after the mold is disassembled. To do. Therefore, the casting manufacturing method using the papermaking part for casting manufacturing according to the present invention can simplify the processing of the waste and reduce the processing cost as compared with the conventional method, and can also reduce the generation amount of the waste.
In addition, if a papermaking part with good surface properties pressed by an elastic core is used, a three-dimensional flow path (pouring system) is formed in which the molten metal flow is not disturbed during casting. Further, it is possible to prevent defects in the casting caused by entrainment of air, dust and the like due to the turbulence of the molten metal flow.
Furthermore, by forming a papermaking part for casting production according to the present invention with a slurry in which organic fibers, inorganic fibers and a binder are mixed, the generation of flames during casting is suppressed as compared with papermaking parts produced using only organic fibers. In addition, it can prevent strength reduction due to burning loss of organic fibers, cracking due to thermal shrinkage due to thermal decomposition (carbonization) of organic binder, and as a result, product defects due to mixing of casting sand into molten metal Occurrence can be prevented.
Moreover, since the papermaking part for casting production according to the present invention has air permeability, gas generated during pouring escapes to the casting sand side. Therefore, generation | occurrence | production of the inferior goods resulting from what is called a nest in a casting can be prevented.
The papermaking part for producing a casting according to the present invention is lightweight, and can be easily cut with a simple device, and thus has excellent handleability.

  The present invention is not limited to the above-described embodiment, and can be changed as appropriate without departing from the spirit of the present invention.

  For example, the runner may be provided with length adjusting means. Thereby, it becomes what was further excellent in the handleability. As this length adjusting means, a thread (male screw, female screw) corresponding to one inner surface and the other outer surface is provided in two parts to be connected, and the length is adjusted according to the degree of screwing. Alternatively, in the case of a cylindrical part, there is a method in which a bellows part is provided in the middle part in the length direction and the length is adjusted by expansion and contraction of the bellows part.

  Moreover, the papermaking part for casting manufacture of this invention can also be made into the T-shaped runner 1 'as shown in FIG. 4 besides the form which is not branched like the said runner 1. FIG. Thereby, as shown to the same figure, a pouring path | route can be made into various forms.

  The papermaking part for casting production of the present invention includes runners 2 to 8 for runners, weirs, degassing, hot water, and lifts as shown in FIG. (Not shown), and can also be applied to the runner material on the mold itself or the inner surface of the mold.

  The papermaking part for casting production according to the present invention may be a cylindrical runner having a puddle. The puddle exhibits a filter effect and enables the production of a casting with higher purity.

  In the above embodiment, a novolac type phenol resin is used, but a resol type phenol resin can also be used. In that case, it is possible to form a runner by making paper with a slurry not containing a resol type phenolic resin, impregnate the resin after dehydrating the runner. It is also possible to heat treat the impregnated phenol resin after drying the runner.

  The casting production method of the present invention can be applied to casting of non-ferrous metals such as aluminum and its alloys, copper and its alloys, nickel, lead, etc. in addition to molten metal (cast iron).

  Hereinafter, the present invention will be described more specifically with reference to examples.

[Example 1]
After making a predetermined fiber laminate using the following raw material slurry, the fiber laminate is dehydrated and dried, and has a shape shown in FIG. 2 (a) and has the following physical properties (for casting production) Papermaking parts, weight about 16 g) were obtained.

<Preparation of raw material slurry>
An organic fiber and an inorganic fiber having the following composition are dispersed in water to prepare a slurry of about 1% (the total weight of the organic fiber and the inorganic fiber is 1% by weight with respect to water). An agent was added to prepare a raw material slurry having a mixing ratio (weight ratio) of organic fiber, inorganic fiber, and binder of the following values.

[Combination of raw slurry]
Organic fiber: used newspaper, average fiber length 1mm, freeness (hereinafter also referred to as CSF) 150cc
Inorganic fiber: Carbon fiber (made by Toray Industries, Inc., trade name “Treka chop”, fiber length 3 mm) is applied to a beater, and organic fiber, inorganic fiber, and phenol resin are mixed in a 2: 3: 5 slurry by weight. Obtained. The freeness of the fiber laminate made from the slurry was 300 cc.
Binder: Phenolic resin (Asahi Organic Materials Co., Ltd., SP1006LS)
Flocculant: Polyacrylamide flocculant (Mitsui Cytec Co., Ltd., A110)
Dispersion medium: water Weight mixing ratio of organic fiber, inorganic fiber and binder = 2: 3: 5

<Paper making and dehydration process>
As the papermaking mold, a mold having a cavity forming surface corresponding to FIG. 2 (a) was used. A net having a predetermined opening is arranged on the cavity forming surface of the mold, and a plurality of communication holes are formed to communicate the cavity forming surface with the outside. In addition, this metal mold | die consists of a pair of split mold.
The raw slurry is circulated by a pump, and a predetermined amount of slurry is pressurized and injected into the papermaking mold, while water in the slurry is removed through the communication hole, and a predetermined fiber laminate is deposited on the surface of the net. I let you. When injection of a predetermined amount of the raw material slurry was completed, pressurized air was injected into the papermaking mold to dehydrate the fiber laminate. The pressure of the pressurized air was 0.2 MPa, and the time required for dehydration was about 30 seconds.

<Curing agent application process>
A curing agent (hexamethylenetetramine) in an amount corresponding to 15% (weight ratio) of the binder was dispersed in water and uniformly applied to the entire surface of the resulting fiber laminate.

<Drying process>
As the drying mold, a mold having a cavity forming surface corresponding to FIG. The mold is formed with a large number of communication holes that communicate the cavity forming surface with the outside. The mold is composed of a pair of split molds.
The said fiber laminated body which apply | coated the said hardening | curing agent was picked out from the papermaking type | mold, and it was transferred to the dry type | mold heated at 220 degreeC. Then, a bag-shaped elastic core is inserted from the upper opening of the dry mold, and a pressurized fluid (pressurized air, 0.2 MPa) is injected into the elastic core in a sealed dry mold. Then, the core was expanded, and the fiber laminate was pressed against the inner surface of the dry mold with the core, and the inner shape of the dry mold was transferred to the surface of the fiber laminate and dried. After performing pressure drying for a predetermined time (180 seconds), the pressurized fluid in the elastic core is removed, the elastic core is contracted and taken out from the drying mold, and the molded body is taken out from the drying mold and cooled. did.

<Cutting and assembly process>
The obtained molded body was cut as shown in FIG. 2B and fitted as shown in FIG. 1 to obtain a runner for the gate.

<Physical properties of the runner>
Thickness: 0.8-1.0mm

[Example 2]
After making a predetermined fiber laminate using the following raw material slurry, the fiber laminate was dehydrated and dried to obtain an intermediate molded body having the shape shown in FIG. Then, the intermediate molded body was impregnated with a binder as described below, dried and heat-cured to obtain a runner for a gate (papermaking part for casting production, weight of about 28 g) having the following physical properties.

<Preparation of raw material slurry>
An organic fiber and an inorganic fiber having the following composition are dispersed in water to prepare a slurry of about 1% (the total weight of the organic fiber and the inorganic fiber is 1% by weight with respect to water). An agent was added to prepare a raw material slurry having a mixing ratio (weight ratio) of organic fiber, inorganic fiber, and binder of the following values.

[Combination of raw slurry]
Organic fiber: used newspaper, average fiber length 1mm, CSF 150cc
Inorganic fiber: Carbon fiber (manufactured by Toray Industries, Inc., trade name “Treka chop”, fiber length 3 mm) was applied to a beater to prepare a slurry in which the organic fiber and the inorganic fiber had a weight mixing ratio of 2: 1. The freeness of the fiber laminate obtained from the slurry was 300 cc.
Binder: Obsidian (Kinsei Matec Co., Ltd., trade name “Nice Catch”)
Paper strength reinforcement: Polyvinyl alcohol fiber (5% organic fiber weight)
Flocculant: Polyacrylamide flocculant (Mitsui Cytec Co., Ltd., A110)
Dispersion medium: water Weight mixing ratio of organic fiber, inorganic fiber and binder = 20: 10: 40

<Paper making and dehydration process>
Papermaking was performed in the same manner as in Example 1 to obtain a fiber laminate, which was dehydrated.

<Drying process>
The same mold as in Example 1 was used as the drying mold.
The said fiber laminated body was taken out from the papermaking type | mold, and it was transferred to the dry type | mold heated at 220 degreeC. A bag-like elastic core was inserted from the upper opening of the dry mold, and an operation was performed according to Example 1 to obtain an intermediate molded body.

<Binder impregnation step>
The obtained intermediate molded body was cut as shown in FIG. 2B and immersed in a binder (resol type phenol solution) bath to impregnate the entire molded body with the binder.

<Dry curing process>
The intermediate molded body was dried in a drying furnace at 150 ° C. for about 30 minutes and the binder was thermally cured.
The weight ratio of organic fibers, inorganic fibers, and binder (obsidian + phenol resin) in the obtained intermediate molded body was 20:10:55 (40 + 15).

<Cutting and assembly process>
The obtained intermediate molded body was cut as shown in FIG. 2 (b) and fitted as shown in FIG. 1 to obtain a runner for the gate.

<Physical properties of the runner>
Thickness: 0.7-1.1mm

<Manufacture of castings>
Using the runners obtained in Examples 1 and 2, a pouring system as shown in FIG. 3 was partially configured, a casting mold was formed, and molten metal (1400 ° C.) was injected from the receiving port.

<Evaluation of runners after casting production>
No violent flames from blowing back or lifting to the receiving port were observed in any runner case. Further, when the mold was disassembled after casting, the runner covered the solidified metal inside and was easily removed from the metal by blasting.

  As described above, the runners (casting parts) obtained in Examples 1 and 2 are suppressed in thermal contraction due to thermal decomposition and form a pouring system or the like corresponding to various mold cavity shapes. It was confirmed that it was excellent in handleability.

It is a half sectional view showing typically one embodiment which applied a papermaking part for casting manufacture of the present invention to a runner for gates. It is a schematic half sectional view of the intermediate molded body of the embodiment, (a) is a diagram showing a state before cutting, (b) is a diagram showing a state after cutting. It is a perspective view which shows typically the state which has arrange | positioned the casting manufacture components of this invention. It is sectional drawing which shows typically the connection state of other embodiment in the papermaking components for casting manufacture of this invention.

Explanation of symbols

1 Runner for pouring gate (papermaking parts for casting production)
2 Runner for receiving port 3 Runner for runner 4 Runner for weir 5 Runner for degassing 6, 7 Runner for raising hot water 8 Runner for lifting 9 Mold

Claims (13)

  A papermaking part for producing castings containing organic fiber, inorganic fiber and binder.   The organic fiber content is 10 to 70 parts by weight, the inorganic fiber content is 1 to 80 parts by weight, the binder content is 10 to 85 parts by weight, and the organic fiber, The papermaking part for casting production according to claim 1, wherein the total of the inorganic fibers and the binder is 100 parts by weight.   The papermaking part for casting manufacture according to claim 1 or 2, wherein the binder contains two or more kinds of binders having different melting points or thermal decomposition temperatures.   The papermaking part for casting production according to any one of claims 1 to 3, wherein the binder is an organic binder and / or an inorganic binder. For casting papermaking component according to claim 1 wherein the inorganic binder is a compounds mainly composed of SiO _2.   The papermaking part for casting production according to any one of claims 1 to 5, wherein the organic fiber is paper fiber.   The papermaking part for casting production according to any one of claims 1 to 6, wherein the papermaking part is hollow. The papermaking part for casting manufacture according to any one of claims 1 to 7, further comprising length adjusting means.   The papermaking part for casting manufacture according to any one of claims 1 to 8, wherein the papermaking part is assembled from a plurality of connectable parts.   A casting manufacturing method using the papermaking part for casting production according to any one of claims 1 to 8, wherein the papermaking part for casting production is arranged in foundry sand.   It is a manufacturing method of the papermaking part for casting manufacture in any one of Claims 1-8, Comprising: The process which papers a molded object from the raw material slurry containing the said organic fiber and the said inorganic fiber, and the paper-molded said molded object A method for producing a papermaking part for casting production comprising the step of including the binder.   The method for producing a papermaking part for casting production according to claim 11, wherein the binder is an organic binder and the organic binder is included by impregnation. The method for producing a papermaking part for casting production according to claim 11 or 12, wherein the raw material slurry contains the inorganic binder.

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