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1、Chapter 2 Casting Processes of Metals第二章：金属的铸造工艺A casting may be defined as a metal object obtained by allowing molten metal to solidify in a mold , the shape of the object being determined by the shape of the mold cavity. Casting is basically melting a solid material, heating to a special temperatu
2、re, and pouring the molten material into a cavity or mold, which is in proper shape. Casting has been known by human being since the 4th century B.C.铸造可以被定义为：“ 通过使熔融的金属液在铸型中凝固而得到金属物体 ”，物体的形状由型腔的形状决定。基本上来说，铸造就是将固态材料熔化、加热到一个特定的温度，然后将熔融的材料浇注到有确定形状的型腔或铸型中。早在公元前 4 世纪，铸造就被人类所了解。2. 1 Casting Procedure21 铸造
3、过程In all casting processes six basic factors are involved. These are as follows:所有的铸造工艺都包括六个基本因素。介绍如下：1. A mold cavity, having the desired shape and size and with due allowance for shrinkage of the solidifying metal, must be produced. Any complexity of shape desired in the finished casting must exis
4、t in the cavity. Consequently, the mold material must such as to reproduce the desired detail and also have a refractory character so that it will not be significantly affected by the molten metal that it contains. Either a new mold must be prepared for each casting, or it must be made from a materi
5、al that can withstand being used for repeated castings, the latter being called permanent molds. 1必须制作出一个具有所要求形状、大小和由于金属凝固过程收缩而造成的应有公差的型腔。在完成的铸件中，所有需求形状的复杂部分都要存在于型腔中，通常，铸型材料必须是为了复制出所需要的零件，同时要有一定的耐火特性以确保它不会被所包容的熔融金属严重影响，每一次铸造都要准备一个新的铸型，或者必须使用一种能够经受重复铸造的模型材料，后者被称为金属模。2. A suitable means must be availa
6、ble for melting the metal that is to be cast, providing not only adequate temperature, but also satisfactory quality and quantity at low cost.2与之相匹配的熔化铸造金属方法必须是有效的，其不仅要提供精确的温度，而且要在低成本的基础上提供令人满意的质量和数量。3. The molten metal must be introduced into the mold in such a manner that all air or gases in the m
7、old, prior to pouring or generated by the action of the hot metal upon the mold, will escape, and the mold will be completely filled. A quality casting must be dense and free from defects such as air holes.3熔融的金属被引入型腔中时，必须采用这样一种方法：使在浇注或在热的金属液与型腔发生作用之前，铸型中所有空气和气体将会逸出，并使型腔能够充满。4. Provision must be mad
8、e so that the mold will not cause too much restraint to the shrinkage that accompanies cooling after the metal has solidified. Otherwise, the casting will crack while its strength is low. In addition, the design of the casting must be such that solidification and solidification shrinkage can occur w
9、ithout producing cracks and internal porosity or voids.4必须提供补缩以确保型腔不会产生太大由于金属凝固后随冷却收缩引起的应力。否则，当强度太低时，铸件就会开裂且强度很低。另外，铸件设计必须确保在凝固和凝固收缩过程中不会产生裂纹、缩松和缩孔。5It must be possible to remove the casting from the mold so a permanent mold must be made in two or more sections.5必须使铸件能够从型中取出，这就要求金属模必须分为两个或两个以上的部分。6A
10、fter removal from the mold, finishing operations may need to be performed to remove extraneous material that is attached to the casting as the result of the method of introducing the metal into the cavity, or is picked up from the mold through contact with the metal.6将铸件从型腔中移出后，可能需要一些清理操作，以除去由于金属引入型
11、腔或金属与模型接触而附属于铸件的多余部分。2. 2 Casting Terms22 铸造术语In the following sections, the details of sand casting process which represents the basic process of casting would be seen. Because going into the details of the process, defining a number of casting vocabulary words would be appropriate. Reference may p
12、lease be made to Fig. 2.1在下面的部分，将会介绍代表着最基本铸造工艺的砂型铸造工艺细节，由于要进行工艺细节的探讨，定义一些铸造用词汇是十分必要的，参考如图 2.1Flask: A moulding flask is one which holds the sand mould intact. Depending upon the position of the flask in the mould structure it is referred to by various names such as drag-lower moulding flask, cope-up
13、per moulding flask and cheek-intermediate moulding flask used in three-piece moulding. It is made up of wood for temporary applications and more generally of metal for long-term use. 砂箱：一个造型用砂箱就是保持砂型完整无缺，依据砂箱在铸型结构中位置，其被冠以多个名字，比如在三箱造型中使用的下型砂箱、上型砂箱和中型砂箱。短期使用由木头构成；长期使用通常用金属制作。Pattern: Pattern is a repl
14、ica of the final object to be made with some modifications. The mould cavity is made with the help of the pattern.模样：模样是经过一些修改的最终产品的复制品，型腔是在模样的帮助下制作出来的。Parting Line: This is the dividing line between the two moulding flasks that makes up the sand mould. In split pattern it is also the dividing line
15、between the two halves of the pattern.分型线：它是组成砂型两砂箱之间的分离线，在劈模中，它也是模样两半型之间的分型线。Bottom board: This is a board normally made of wood which is used at the start of the mould making. The pattern is first kept on the bottom board, sand is sprinkled on it and then ramming is done in the drag.底板: 它通常是一个用木头制
16、作、用于造型开始时的平板，首先把模样放在底板上，然后将砂洒在模样上，然后在下箱中捣实。Facing sand: The small amount of carbonaceous material sprinkled on the inner surface of the moulding cavity to give a better surface finish to the castings.面砂：少量洒在型腔内表面以得到更好的铸件表面光洁度的含碳材料。Fig. 2.1 Cross section of a sand mouldMoulding sand: It is the freshly prepared refractory material used for making the mould cavity. It is a mixture of silica, clay and moisture in appropriate proportions to g
