Machining process of aluminum alloy castings for reducer gearboxes
Release time:
2025-02-11
Preliminary Preparations
Design Drawings: Based on the function, structure, and performance requirements of the speed reducer gearbox, detailed 3D modeling and 2D drawings are designed using professional CAD/CAM software, indicating the dimensions, tolerances, surface roughness, and technical requirements of each part.
Material Selection: Select appropriate aluminum alloy materials, such as A356 and A380 in the Al-Si series alloys with good casting and mechanical properties, based on the gearbox's operating environment and load characteristics.
Mold Making: According to the design drawings, materials such as mold steel are processed using equipment such as CNC machining centers to create molds that match the shape and size of the castings.
Casting
Melting: The selected aluminum alloy raw materials are placed in a furnace and heated to an appropriate temperature to melt them, generally around 700℃-750℃. During the melting process, an appropriate amount of refining agent and modifier is added to remove impurities and gases and adjust the alloy composition.
Pouring: The melted aluminum alloy liquid is poured into a mold preheated to a certain temperature. The pouring temperature is generally controlled at 680℃-730℃. The casting speed and pressure are controlled to ensure that the aluminum alloy liquid can fill the mold cavity smoothly and quickly.
Cooling and Solidification: The aluminum alloy liquid in the mold gradually solidifies and forms under natural cooling or forced cooling conditions. For some large or complex castings, forced cooling methods such as air cooling and water cooling may be used.
Quality Inspection
Appearance Inspection: Inspect the surface of the casting for defects such as cracks, pinholes, pores, shrinkage cavities, inclusions, burrs, and flash using visual inspection or tools such as magnifying glasses and microscopes.
Size Inspection: Use measuring tools such as calipers, micrometers, and three-coordinate measuring instruments to measure the key dimensions of the casting to ensure that the dimensional deviations are within the design tolerance.
Non-destructive Testing: Use non-destructive testing techniques such as ultrasonic testing, radiographic testing, and magnetic particle testing to detect internal defects such as cracks, pores, looseness, and inclusions in the casting.
Mechanical Property Testing: Samples are taken from the casting for tensile tests, hardness tests, impact tests, and other mechanical property tests to verify that the strength, hardness, and toughness of the casting meet the design requirements.
Assembly and Packaging
Assembly: Assemble the processed speed reducer gearbox with other components, such as gears, shafts, bearings, and seals, according to the assembly drawing, ensuring that the installation positions of each component are accurate and the clearances are appropriate.
Debugging: The assembled speed reducer is subjected to no-load debugging and load debugging to check whether its operation is stable, whether there is any abnormal noise, and whether the temperature rise is normal. Any problems found are promptly adjusted and resolved.
Packaging: The qualified speed reducer gearbox is cleaned and then packaged and stored according to customer requirements and transportation needs, selecting appropriate packaging materials and methods.
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