JB/T 5000.4-1998 General technical conditions for heavy machinery castings
Some standard content:
JB/T5000.4-1998
Foreword
This standard adopts the German SMS SN200/5 "Processing Specification MS-001-0003 "Casting Inspection Standard" and supplements and refines the relevant technical requirements for cast iron parts. Castings" and Japan Tateshima Shipbuilding Co., Ltd.
When there are no special requirements in product drawings and technical documents, they shall comply with the provisions of this standard. Appendix A of this standard is the appendix of the standard.
This standard is proposed and managed by the Metallurgical Equipment Standardization Technical Committee of the Ministry of Machinery Industry. The responsible drafting unit of this standard: First Heavy Machinery Group Corporation. The participating drafting unit of this standard: Xi'an Heavy Machinery Research Institute. The main drafters of this standard: Duan Xiuming and Lu Jiade. 399
1 Scope
Standards of the Machinery Industry of the People's Republic of China
General Technical Conditions for Heavy Machinery
Iron Casting
The heavy mechanical general techniques and standardsIron casting
This standard specifies the technical requirements, test methods, acceptance rules, marking and certification of iron castings. JB/T 5000.4--. 1998
This standard applies to gray iron castings, ductile iron castings and heat-resistant iron castings cast in sand molds or molds with thermal conductivity similar to sand molds in heavy machinery.
2 Referenced standards
The provisions contained in the following standards constitute the provisions of this standard through reference in this standard. When this standard is published, the versions shown are valid. All standards are subject to revision, and parties using this standard should explore the possibility of using the latest versions of the following standards. GB1348--88 Ductile iron castings
GB/T6060.1-·1997 Surface roughness comparison sample casting surface GB6414—86 Casting size tolerances
GB9437—88 Heat-resistant cast iron castings
GB9439·88 Grey cast iron castings
GB/T11351—89. Casting weight tolerances
JB/T5000.12--1998 General technical conditions for heavy machinery Coating 3 Technical requirements
3.1 Cast iron grade, chemical composition and mechanical properties 3.1.1 Grey cast iron grade and mechanical properties shall be in accordance with GB9439. The chemical composition shall be determined by the supplier, but it must meet the brand and corresponding mechanical property indicators specified in G139139. When there are special requirements for chemical composition, the supplier and the buyer shall agree on it. 3.1.2 Ductile iron grades and mechanical properties shall be in accordance with GB1348. The chemical composition shall be determined by the supplier, but it must meet the grades and corresponding mechanical properties specified in GB1318. When there are special requirements for chemical composition, the supplier and the buyer shall agree on it. 3.1.3 Heat-resistant cast iron grades, chemical composition and mechanical properties shall be in accordance with GB9437. 3.2 Dimensional tolerances and tolerance zone configuration
3.2.1 Casting dimensional tolerances shall be in accordance with GB6414. Common grade codes and tolerances are shown in Table 1. The same tolerance grade shall be used for all castings, and the tolerance grade shall be selected according to the maximum size of the rough part.
Approved by the State Machinery Industry Bureau on September 30, 1998
Implementation on December 1, 1998
Basic dimensions of rough castings
10
10
16
25
40
63
100
160
250
400
630
1000
1600
2500
4000
6300
Note
1 6
25
40
63
100
160
250
400
630
1000
1600
2500
4000
6300
10000
CT8
1.0
1. 1
1.2
1.3
1.4
1.6
1.8
2.0
2.2
2.6
2.8
3.2
3.8
4.4
Casting dimension tolerances do not include draft angle. JB/T 5000.4—1998
Table 1
CT9
1. 5
1.6
1.7
1.8
2.0
2.2
2.5
2.8
3.2
3.6
4.0
4.6
5.4
6.2
7.0
Dimensional tolerance of cast iron parts
Tolerance grade
CT10
2.0
2.2
2.4
2.6
2.8
3. 2
3.6
4.0
4.4
5.0
6.0
7.0
8.0
9.0
10.0
11.0
CT11
2.8
3. 0
3.2
3.6
4.
4.4
5. 0
5.6
6.2
7.0
8.0
9.0
10.0
12.0
14.0
16.0
1CT13
CT12
4.2
4.4
4.6
5.0
5.6
6.0
7.0
8.0
9.0
10.0| |tt||11.0
13.0
15.
17.0
20.0
23.0
8
9
10
11
12
14
16
18
21
24
28
32
CT14
8
9
10
11
12
14
16
18
20
23
26
30
35
40
CT1
16
1E
12
14
16
18
20
22
25
29
33
38
.
50
n
(T16
12
14
1
18
20
22
25
28
32
337
2
49
56
6
Where drawings and technical documents do not specify, the dimensional tolerance grade of small batch and single piece production castings shall be selected according to the grade recommended in the black frame: the dimensional tolerance grade of batch and mass production castings shall be increased by two grades accordingly3.2.2. The casting size tolerance zone should be symmetrical to the basic size configuration of the casting, that is, half of the tolerance is on the positive side and the other half is on the negative side (see Figures 1 and 2). When there are special requirements, the tolerance zone can also be configured asymmetrically, but it should be marked on the drawing or specified in the technical document. The basic dimensions of casting roughness refer to:
The dimension between two non-machined surfaces marked in the drawing; the non-machined inner and outer diameters, fillets and arcs marked in the drawing: the machined dimensions marked in the drawing plus machining allowance (see Figure 1 and Figure 2). Basic rough size of castings
8
Minimum limit size
Maximum limit size
Figure 1 Limit size of castings
401
JB /T5000.4-1998
Machining allowance
Half casting tolerance
Machining final surface one
Basic size of casting roughness
Figure 2 The relationship between machining allowance and dimensional tolerance of castings 3.2.3 Castings have inclined parts, and their dimensional tolerance zones should be arranged symmetrically along the inclined plane (see Figure 3). Dimensional tolerance zone of castings
degree
Figure 3 Dimensional tolerance zone of inclined parts
3.2.4 Unless otherwise specified, the wall thickness dimensional tolerance level can be downgraded for selection. As shown in the drawing, the general dimensional tolerance is CT12, and the wall thickness dimensional tolerance is CT13.
3.2.5 The minimum limit size of non-machined cast internal and external fillets or arcs is the dimension marked on the drawing, and the maximum limit size is the dimension marked on the drawing plus the tolerance value.
3.3 Mistype (wrong box) value
Mistype (see Figure 4) must be within the tolerance value specified in Table 1. When the mistype value needs to be further restricted, it should be marked on the drawing, and the value should be selected from Table 3 of GB6414-86, and should not be added to the value listed in Table 1. Wrong type
402
Wrong type
Wrong type
Picture 4 Wrong type
3.4 ??machining allowance
JB/T 5000.4- 1998
3.4.1 The machining allowance refers to the machining allowance of a surface. The values ??are shown in Table 2. For a rotating body or two surfaces, the total surface processing residue to be added should be calculated as 2 times.
Table 2 machining allowance
Casting plus
Maximum size of casting
180
>180~500
500~800|| tt||8001250
1250 1600
1600~2500
22500~3150
3150~6300
≥6300~~10000
&
Mechanical addition does not include draft angle
Small batch and single piece production
Single side of casting
4
5||tt ||8
10
12
15
17
20
amount
remainder
Batch and mass production
Single face of casting
3
4
10
13
17
Hongheshun Surface addition amount
imt
2 When producing small batches and single pieces, the "maximum size of castings" refers to the maximum length, width, height or diameter of castings; when producing batches and mass production, "castings' maximum size" "Maximum size" refers to the larger of the largest basic size on the surface requiring processing and the distance between the surface and its processing base. 3.4.2 The machining allowance is selected according to the maximum size of the casting. 3.4.3 For castings with secondary processing (referring to returning to the casting machine for finishing after rough processing or finishing after secondary aging), the machining allowance is 1.2 to 1.5 times that of Table 2.
3.4.4 Example of calculation of rough size of castings (see Table 3). See Figure 5 for cast iron rings (single piece production).
Casting size tolerance class CT12.
The maximum size of cast iron ring is 1000mm. The machining allowance of each surface (according to Table 2) is 8mm. .2/
3.2
$500
medium 1000
Figure 5 cast iron ring
403
nominal size of processed parts||tt ||1000
500
100
Machining allowance
+2x8
2×8-2×2
+2× 811×2
Note: Casting rough dimensions do not include draft angle, 3.5 casting weight tolerance
JB/T 5000.4--1998
Cast iron ring rough dimensions|| tt | |Cast
The minimum size is small
1010.5
175
115
pieces
The maximum size is
1021.5|| tt||185
121
mm
The weight tolerance of castings shall be implemented in accordance with the provisions of GB/T11351. When the weight tolerance of castings is used as the basis for acceptance, it should be stated in the drawing or technical document.
3.6 Bone cutting allowance and related disposal
3.6.1 The riser cutting allowance of castings is according to Table 4. Table 4 Riser cutting allowance of castings
Ca
Residual traces of riser
Maximum protrusion value
Sag
60
>60
100
100
~~200
7
door
>200
300||tt ||10
root
部
>300
400
1.
most
too||tt ||400
-500
16
foot
inch
2500
600
18||tt| |2600
-800
25
shall not exceed 1/2 of the machining allowance there. There must be a minimum machining allowance of 3~5mm. 3.6.2 When the casting is exposed When the opening is set on a non-machined surface, it should be ground and smoothed to meet the surface quality requirements. 3.6.3 Casting stomach should be removed before heat treatment. 3.7 Surface quality requirements
3.7.1 The molding sand, core sand, core bone, flesh, sticky sand, sand inclusions, etc. on the castings should be smoothed and cleaned. 3.7.2 Wrong shapes, misaligned bosses, etc. should be corrected to achieve a smooth transition to ensure appearance quality. 800 | | tt | | 100 | | tt | | 32 | | tt | The defects should be removed by processing; b) The pits on the non-machined outer surface of the casting shall not exceed the requirements in Table 5. Table 5 Allowable pit size casting weight within the range of 100mm×100mm
Pit size and quantity
2000kg
2- mm, depth 2 mm, 3 pieces||tt ||2000kg
mm
-10or
50
3~-6mm deep 3mm.3 pieces
Note: For castings weighing no more than 2000kg, Scattered pits not larger than 2mm are not counted: For castings weighing more than 2000kg, loose pits not larger than $3mm are not counted
3.7.4 Wrinkles on the non-machined surface of castings, the depth is less than 2mm, and the spacing should be greater than 100mm . 3.7.5 Defects that are not allowed in castings:
a) Casting defects that affect the performance of castings, such as cracks, cold shuts, shrinkage cavities, slag inclusions, etc.; b) Important threaded holes and rolling smooth parts Casting defects on surfaces such as surfaces, treads of rollers, etc.; c) Defects on non-machined surfaces causing leakage; d) Defects on other important working surfaces noted in the ordering documents. 3.7.6 Requirements for the roughness of the machined surface of castings 3.7.6.1 The surface roughness of the castings shall comply with the requirements of Table 6. 404
Manual dry type
Ra50
JB/T5000.4.-.1998
Table 6 Non-machined surface roughness of castings
Machine dry type
Ras50
Wet type
Ra100
μm
3.7.6.2 The surface roughness of castings is in accordance with GB/T6060.1 Comparative inspection of specified comparison sample blocks or self-made comparison samples. The comparison sample is selected and determined through negotiation between the supplier and the buyer. When 80% of the surface area of ??the casting is no less than that of the comparison sample, it is considered qualified. Castings are also considered qualified when the surface of the casting is confirmed by the inspector to be no lower than that of the comparison sample. 3.7.7 If the casting is shot peened, the surface roughness shall be based on that after shot peening. 3.8 Repair welding of castings
3.8.1 Castings can be repaired with the consent of the technical inspection department and the approval of the purchaser under the condition of ensuring the performance and appearance quality. 3.8.2 The repair welding must be carried out during repair welding. Clean the parts and expose the base metal to ensure the quality of repair welding. During repair welding, a reliable repair welding process should be formulated based on the material, shape, structure, and usage requirements of the casting and should be strictly implemented during the repair welding process. 3.8.3 Cast iron parts that require high precision and stability and are likely to generate large stress during the repair welding process should be stress relieved, except for defects found after cold working that are repaired with cast 308 electrodes. 3.9 Shot blasting and priming
3.9.1 The non-machined surfaces of machine product castings need to be shot blasted or roller cleaned to meet the cleanliness requirements of Sa2 point level. 3.9.2 Castings should be primed within 6 hours after final shot blasting. When applying primer, the temperature of the casting itself and the ambient temperature must not be lower than the temperature allowed for painting. Before painting, dust and other objects on the castings should be cleaned with oil-free and water-free compressed air or a vacuum cleaner. 3.9.3 The requirements for painting shall be in accordance with the relevant provisions of JB/T5000.12. 4 Test methods
4.1 The test methods for gray iron castings are in accordance with the provisions of GB9439. 4.2 The test methods for ductile iron castings are in accordance with CB1348. 4.3 The test method for heat-resistant iron castings shall be in accordance with the provisions of GB9437. 5 Acceptance rules
5.1 Inspection rights and inspection locations
5.1.1 Castings shall be inspected and accepted by the supplier's technical inspection department. The manufacturer has the right to inspect the castings. When the demander requests to participate in the supplier's inspection. Both parties should agree on a date for submission of inspections. If the purchaser fails to arrive at the agreed time, the supplier can conduct its own inspection and submit the inspection results to the purchaser. 5.1.2 Unless the supply and demand parties agree that inspection can only be done on the demand side, the final inspection is generally carried out on the supplier side. When there is a dispute between the supplier and the buyer about the quality of castings, the inspection can be conducted by a third party agreed upon by both parties. 5.2 Delimitation of batches
5.2.1 Castings poured from the same package of molten iron are considered to be a batch. 5.2.2 The maximum weight of each batch of castings is 2000kg after cleaning. The weight of the batch can be changed by agreement between the supplier and the buyer. 5.2.3 If the weight of a casting is greater than or equal to 2000kg, it will be regarded as a batch. 5.2, 4 When a large amount of molten iron of the same brand is continuously melted, the castings poured within 2 hours are regarded as a batch. 5.3 Number of tests, evaluation and retest of test results 5.3.1 When testing tensile strength or impact value , take at least 1 tensile specimen or -·group of 3) impact specimens from each batch for testing. If the test results meet the requirements, the batch of castings is qualified. If the test results do not meet the requirements, repeat the test with double samples of the same batch. 5.3.2 When the repeated test results meet the requirements, the batch of castings is qualified; if 1/2 of the double repeated tests fail to meet the requirements, the batch of castings is unqualified.
If the product is unqualified due to improper heat treatment, it is allowed to be heat treated again, but the number of repeated heat treatments shall not exceed 2 times. 5.3.3 Each batch of heat-resistant iron castings should be analyzed for chemical composition. If the chemical composition is unqualified, double samples from the same batch are allowed to be used 405
JB/T 5000.4
--- 1998 | | tt | The representative test block shall be re-tested after heat treatment.
5.4 Geometry and dimensions
The geometry and dimensions of the first batch of castings and important castings should be inspected piece by piece according to the drawings. General castings and usage guarantees. Castings produced by the dimensional stability method can be randomly inspected, and the spot inspection method shall be carried out according to the method agreed by both parties. 5.5 The surface quality of the casting shall be accepted according to the requirements of 3.7
If it is not due to the quality problem of the casting itself, but When the test results do not meet the requirements due to one of the following reasons, the test is invalid:
a) The specimen is improperly installed on the testing machine or the testing machine is improperly operated; b) The specimen has casting defects or Improper cutting of the specimen; c) The tensile specimen breaks outside the gauge length;
d) There are casting defects on the fracture surface of the specimen after stretching and impact. 5.7 The physical and chemical inspection items of cast iron parts are shown in Appendix A ( Standard Appendix). 6 Marking and Certification
6.1 Important or individually ordered castings should have the manufacturer's mark. 6.2 The location, size and method of the mark should be agreed upon by both parties, but care should be taken not to overwhelm the casting. The quality is damaged. 6.3 Castings should be accompanied by a quality certificate signed by the supplier's inspection department. The certificate should include the following: a) Manufacturer's name or factory logo;
b) Part number or order contract No.:
c) Material grade; bzxZ.net
d) Main inspection results.
406
A1
The physical and chemical inspection items of iron castings are shown in Table A1.
JB/T 5000.4-1998
Appendix A
(Appendix to the subject matter)
Physical and chemical inspection of iron castings
Table A1
Materials
Gray cast iron
Ductile iron||tt ||Heat-resistant cast iron
Jiang: "—
Chemical composition
Physical and chemical inspection items of cast iron
Science
Strength
Resistance Tensile strength
+
十
-
” is a required inspection item and “一” is a random inspection item. Zhongchang rate
Sex
Power
Divine toughness
Hardness
Gold
Phase|| tt||407
1. When testing the tensile strength or impact value, at least 1 tensile specimen or a group of 3 impact specimens from each batch shall be taken for testing. If the test results meet the requirements, the batch of castings is qualified. If the test results do not meet the requirements, repeat the test with double samples of the same batch. 5.3.2 When the repeated test results meet the requirements, the batch of castings is qualified; if 1/2 of the double repeated tests fail to meet the requirements, the batch of castings is deemed unqualified.
If the product is unqualified due to improper heat treatment, it is allowed to be heat treated again, but the number of times of repeated heat treatment shall not exceed 2 times. 5.3.3 Each batch of heat-resistant iron castings should be analyzed for chemical composition. If the chemical composition is unqualified, double samples from the same batch are allowed to be used 405
JB/T 5000.4
--- 1998 | | tt | The representative test block shall be re-tested after heat treatment.
5.4 Geometry and dimensions
The geometry and dimensions of the first batch of castings and important castings should be inspected piece by piece according to the drawings. General castings and usage guarantees. Castings produced by the dimensional stability method can be randomly inspected, and the spot inspection method shall be carried out according to the method agreed by both parties. 5.5 The surface quality of the casting shall be accepted according to the requirements of 3.7
If it is not due to the quality problem of the casting itself, but When the test results do not meet the requirements due to one of the following reasons, the test is invalid:
a) The specimen is improperly installed on the testing machine or the testing machine is improperly operated; b) The specimen has casting defects or Improper cutting of the specimen; c) The tensile specimen breaks outside the gauge length;
d) There are casting defects on the fracture surface of the specimen after stretching and impact. 5.7 The physical and chemical inspection items of cast iron parts are shown in Appendix A ( Standard Appendix). 6 Marking and Certification
6.1 Important or individually ordered castings should have the manufacturer's mark. 6.2 The location, size and method of the mark should be agreed upon by both parties, but care should be taken not to overwhelm the casting. The quality is damaged. 6.3 Castings should be accompanied by a quality certificate signed by the supplier's inspection department. The certificate should include the following: a) Manufacturer's name or factory logo;
b) Part number or order contract No.:
c) Material grade;
d) Main inspection results.
406
A1
The physical and chemical inspection items of iron castings are shown in Table A1.
JB/T 5000.4-1998
Appendix A
(Appendix to the subject matter)
Physical and chemical inspection of iron castings
Table A1
Materials
Gray cast iron
Ductile iron||tt ||Heat-resistant cast iron
Jiang: "—
Chemical composition
Physical and chemical inspection items of cast iron
Science
Strength
Resistance Tensile strength
+
十
-
” is a required inspection item and “一” is a random inspection item. Zhongchang rate
Sex
Power
Divine toughness
Hardness
Gold
Phase|| tt||407
1. When testing the tensile strength or impact value, at least 1 tensile specimen or a group of 3 impact specimens from each batch shall be taken for testing. If the test results meet the requirements, the batch of castings is qualified. If the test results do not meet the requirements, repeat the test with double samples of the same batch. 5.3.2 When the repeated test results meet the requirements, the batch of castings is qualified; if 1/2 of the double repeated tests fail to meet the requirements, the batch of castings is deemed unqualified.
If the product is unqualified due to improper heat treatment, it is allowed to be heat treated again, but the number of times of repeated heat treatment shall not exceed 2 times. 5.3.3 Each batch of heat-resistant iron castings should be analyzed for chemical composition. If the chemical composition is unqualified, double samples from the same batch are allowed to be used 405
JB/T 5000.4
--- 1998 | | tt | The representative test block shall be re-tested after heat treatment.
5.4 Geometry and dimensions
The geometry and dimensions of the first batch of castings and important castings should be inspected piece by piece according to the drawings. General castings and usage guarantees. Castings produced by the dimensional stability method can be randomly inspected, and the spot inspection method shall be carried out according to the method agreed by both parties. 5.5 The surface quality of the casting shall be accepted according to the requirements of 3.7
If it is not due to the quality problem of the casting itself, but When the test results do not meet the requirements due to one of the following reasons, the test is invalid:
a) The specimen is improperly installed on the testing machine or the testing machine is improperly operated; b) The specimen has casting defects or Improper cutting of the specimen; c) The tensile specimen breaks outside the gauge length;
d) There are casting defects on the fracture surface of the specimen after stretching and impact. 5.7 The physical and chemical inspection items of cast iron parts are shown in Appendix A ( Standard Appendix). 6 Marking and Certification
6.1 Important or individually ordered castings should have the manufacturer's mark. 6.2 The location, size and method of the mark should be agreed upon by both parties, but care should be taken not to overwhelm the casting. The quality is damaged. 6.3 Castings should be accompanied by a quality certificate signed by the supplier's inspection department. The certificate should include the following: a) Manufacturer's name or factory logo;
b) Part number or order contract No.:
c) Material grade;
d) Main inspection results.
406
A1
The physical and chemical inspection items of iron castings are shown in Table A1.
JB/T 5000.4-1998
Appendix A
(Appendix to the subject matter)
Physical and chemical inspection of iron castings
Table A1
Materials
Gray cast iron
Ductile iron||tt ||Heat-resistant cast iron
Jiang: "—
Chemical composition
Physical and chemical inspection items of cast iron
Science
Strength
Resistance Tensile strength
+
十
-
” is a required inspection item and “一” is a random inspection item. Zhongchang rate
Sex
Power
Divine toughness
Hardness
Gold
Phase|| tt||407
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