JB/T 5000.5-1998 General technical conditions for heavy machinery non-ferrous metal castings
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JB/T5000.5-1998
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Preface
This standard is non-equivalent to the German SMS company (SMS) SN200/5 standard and combined with the advanced experience of my country's machinery industry And formulated.
When there are no special requirements in the design drawings and technical documents. All shall comply with the provisions of this standard. This standard is proposed and administered by the Metallurgical Equipment Standardization Technical Committee of the Ministry of Machinery Industry. The unit responsible for drafting this standard: No.-Heavy Machinery Consolidated Company. The organization participating in the drafting of this standard: Xi'an Heavy Machinery Research Institute. The main drafters of this standard: Li Xuemin, Geng Baohua. 362
Mechanical Industry Standards of the People's Republic of China
General technical conditions for heavy machinery
Non-ferrous metal castings
The heavy mechanical general techniques and standardsNon-ferrous casting
1 Scope
JB/T5000.5--.1998
This standard specifies the technical requirements, test methods, acceptance rules, marking and certification of non-ferrous metal castings. This standard is applicable to heavy machinery. Copper alloy, aluminum alloy, and zinc alloy castings produced by sand mold, metal mold, and centrifugal casting methods. 2 Referenced standards
The provisions contained in the following standards constitute provisions of this standard by being quoted in this standard. At the time of publication, the editions indicated were valid. All standards are subject to revision and parties using this standard should explore the possibility of using the latest version of the standard listed below. GB/T1173—1995 Cast aluminum alloy
GB/T11751997 Cast zinc alloy
GB1176---87 Cast copper alloy technical conditions GB/T 6060.1-
--1997 Surface roughness Comparison of sample casting surface GB6414---86 casting dimensional tolerance
3 Technical requirements
3.1 Chemical composition and mechanical properties
3.1.1 Chemical composition and mechanical properties of aluminum alloy castings Comply with the regulations of GB/T1173. 3.1.2 The chemical composition and mechanical properties of zinc alloy castings should comply with the regulations of GB/T1175. 3.1.3 The chemical composition and mechanical properties of copper alloy castings should comply with the provisions of GB1176. 3.1.3.1 For copper alloy castings that bear heavy loads and are used in key parts, such as worm gears, rims, hold-down nuts and castings, the maximum size is 500mm. For copper alloy castings, mechanical properties are the main acceptance basis. Slight deviations in chemical composition are allowed, and the allowable deviation value is 10% of the upper and lower limits of the percentage content of each main ingredient.
Various bushings, bearings and slide plates in general parts and with the maximum casting size not exceeding 500mm 3.1.3.2 are suitable for bearing light loads and are used for
copper alloy castings with no chemical composition or mechanical properties. It can be used as the basis for acceptance. If one of the two items is qualified, it can be regarded as qualified. The other item is only for reference, but data must be available.
3.2 Dimensional tolerances and configuration of tolerance zones
3.2.1 Dimensional tolerances should comply with the regulations of GB6414. See Table 1 for commonly used grade codes and tolerances. Select the same tolerance grade for the same casting. The tolerance grade is selected according to the maximum size of the casting roughness. The National Machinery Industry Bureau approved the implementation on 1998-12-01 on 1998-09-30
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1
Basic dimensions of cast hair damage
10
>10~16
≥>16~25
≥25~40
>40~63
>63~100
>100~160
160~250
>250~400
400~630
>6301000
≥1000~1600
>1600~2500
>2500~4000
>4000~6300
≥6300~10000
CT8
1.0
1.1
1.2
1.3
1. 4
1.6
1.8
2.0
2. 2
JB/T5000. 5--1998
Table 1
2.6
2.8
3.2
3.8
4.4
Casting dimensional tolerance values
Tolerance
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||tt| |6.2
7. 0
Single piece and small batch production are selected according to the tolerance level within the black line frame. CT10
2.0
2. 2
2. 4
2.6
2.8
3.2
3.6||tt ||4.0
4. 4
5.0
6.0
7.0
8.0
9. 0
1.0. 0
11.0
The selection tolerance level of batch and mass production is correspondingly higher than that of single piece and small batch production. 2
3 When the drawings and technical documents do not specify, the selection tolerance level should be Complies with tolerance classes in bold outline. Level
CT1
2.8
3.0
3.2
3.6
4.0
4. 4
5.0
5. 6
6. 2
7. 0
8.0
9.0
10.0
12.0| |tt||14.0
16.0
CT12
4. 2
4.4
4. 6
5. 0||tt ||5.6
6.0
7.0
8.0
9.0bZxz.net
10.0
11. 0
13.0||tt ||15. )
17.0
20.0
23.0
mm
CT13
7
8||tt ||10
12
14
16
18
21
24
28
32
3.2.2 Tolerance zone - generally should be symmetrical to the basic size configuration of casting roughness, that is, half of the tolerance is on the positive side and the other half is on the negative side (see Figure 1). When there are special requirements, the tolerance zone can also be configured asymmetrically but should be marked on the drawing. The basic size of the casting
minimum limit size
maximum limit size
picture]
The limit dimensions of castings
The basic dimensions of casting roughness refer to:
The dimensions between two non-machined surfaces marked in the drawing; the non-machined inner and outer diameters, fillets and Arc: the machining dimensions marked in the drawing plus the machining allowance (see Figure 2). 364
JB/T5000.5
1998
Machining allowance
Processing the final table box
Basic rule of casting
Casting Dimensional tolerance
Figure 2 The relationship between machining allowance and casting dimensional tolerance 3.2.3 The wall thickness dimensional tolerance level can generally be reduced by one level. That is, the general dimensional tolerance on the drawing is CT10, and the wall thickness tolerance is 3.2.4 Non-machined casting inner and outer fillets or arcs. The minimum limit size is the size marked on the drawing, and the maximum limit size is marked CT11 on the drawing || tt||Dimensions plus soil tolerance value.
3.2.5 If the casting has an inclined part, its dimensional tolerance zone should be arranged symmetrically along the inclined surface (see Figure 3). Casting ruler ten tolerance zone
angle
Figure 3. Dimensional tolerance zone for inclined parts
3.3 Mistype (wrong box) value
Mistype (see Figure 4) should 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. The value should be selected from Table 3 of GB6414--86, and should not be added to the value listed in Table 1. 365
3.4 ??plus margin
wrong type
JB/T 5000.5
-1998
wrong type
Figure 4 wrong type| |tt||3.4.1 The machining allowance of casting roughness refers to the machining allowance of one surface. The surface machining allowance of a rotating body or two surfaces that need to be processed should be calculated as 2 times.
3.4.2 The machining allowance is selected from Table 2 according to the maximum size of the casting. Table 2 Copper, aluminum and zinc alloy castings plus T. Maximum size of remaining castings
100
100~160
>160~250
250~400|| tt||2400--630
630~1000
>1000~1600
>1600-~2500
?2500~-4000
10006300
>6300~10000
Single piece, small batch bottom, side
2.5
3.5
4.5
5.5||tt| |t
16
0
3.5 Example of calculating the rough size of castings (see Table 3) Copper alloy ring Figure 5.
Casting size tolerance class CT11.
The maximum size of castings is 000mm.
The surface plus the remainder (according to Table 3) is 7mm.
366
Add allowance
Batch, large quantity bottom, side
1.5
3
Add amount for holes and top| |tt||mm
Processing size
1000
500
100
Processing allowance
-+-2×7
JB/T5000.5-1998
3.2
3.5
2X7-2X×2
2x
Note: Casting hair is damaged The draft angle of 10 feet is not included in the shape and size of 3.6. |Dimensional tolerance according to CT11
±4.5
±3. 5
±2.5
cast
bad
pieces||tt| |gross
minimum size
1009.5
478.5
113.5
mm
maximum size
1018.5||tt| |485
118.5
The geometric shape and size of the casting should comply with the requirements of the drawing or ordering technical conditions. The geometric shape and size of the castings should be inspected piece by piece. If the castings are produced in batches, they can be randomly inspected. The spot inspection method shall be negotiated by the supplier and the buyer. 3.7 Surface quality requirements
3.7.1 The roughness of the non-machined surface of castings, Rα for sand mold casting shall not be greater than 50 μm, and Ra for metal mold and centrifugal casting shall not be greater than 25 mm. 3.7.2 The surface roughness of the castings shall be checked against the comparison sample specified in GB/T6060.1 or the self-made comparison sample. 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. When the surface of the casting is confirmed by the inspector to be no lower than that of the comparison sample, it is also deemed to be qualified. 3.7.3 Castings should be free of pouring openings, flying spurs, etc. The remaining amount of the pouring riser on the non-processed surface must be leveled and polished to meet the surface quality requirements. The height of the pouring port residue on the processing surface shall be as specified in Table 4. Table 4 Remaining amount of gate and riser on machined surface
Maximum size of castings
600
>600～1200
>1200
3.7.4 pieces The molding sand, core sand and core bone should be cleaned. Burning concave residual height
10
15
mm
3.7.5 Cold insulation, cracks, penetrating pores, shrinkage, and oxidation are not allowed on castings There are defects such as objects and slag inclusions that affect performance. 3.7.6 The non-machined surface of castings is allowed to have a single defect with a diameter of no more than 3mm, a depth of less than 1/3 of the wall thickness at that location, and a number of no more than 2 per square decimeter. However, defects are not allowed to exist at the corresponding position on the back side of the defect. If there are higher requirements, they should be noted in the drawing or order agreement.
3.7.7 The machined surface of the casting is allowed to have any casting defects that can be removed by mechanical processing. However, the defects must be cleaned up to confirm whether they can be removed during processing.
3.7.8 When castings must be inspected for internal defects, they should be clearly specified in the drawing or agreed upon in the ordering agreement. 3.7.9 The required gas Castings that are airtight or contain liquids should be tested for airtightness or permeability as specified in the drawing or order agreement. 3.8 Repair of defects
3.8.1 Repair is not allowed under the following circumstances:
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JB/T5000.5---1998
—with flammable and explosive or pressure-bearing or sealing parts that are in contact with highly toxic substances; - parts that are subject to high overflow, high pressure, strong corrosion, threaded parts, and main load-bearing parts of heavy loads: - cold insulation and severe blisters, pores, slag holes, shrinkage on castings Defects such as looseness and slag inclusions 3.8.2 Except for the circumstances specified in 3.8.1, castings need to be repaired by welding, and defects determined to be repairable by welding must be repaired by welding or other feasible methods.
3.8.3 During welding repair, the surface should be carefully cleaned and the welding process should be formulated to ensure welding quality. Proper heat treatment should be carried out after welding. 3.8.4 If the casting is deformed, it is allowed to be corrected. After correction, the geometric dimensions and the presence of cracks should be inspected. 4 Test methods
4.1 The chemical composition and mechanical properties of aluminum alloy castings are tested according to the provisions of GB/T1173. 4.2 The chemical composition and mechanical properties of zinc alloy castings are tested according to the provisions of GB/T1175. 4.3 Copper alloy castings The test of chemical composition and mechanical properties shall be in accordance with the provisions of GB1176. 5 Acceptance regulations
5.1 Inspection rights and inspection locations
5.1.1 Castings shall be inspected and accepted by the supplier's technical inspection department. 5.1.2 When the demander requires to participate in the supplier's inspection, both parties should agree on the date for submission of inspection. If the purchaser fails to arrive within the agreed time, the supplier can conduct its own inspection and submit the inspection results to the purchaser. 5.1.3 Unless the supplier and the buyer agree that the inspection can only be carried out on the buyer's side, the final inspection shall be carried out on the supplier's side. 5.1.4 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 Composition of casting batches
5.2.1 For the same smelting heat, if injected within 8 hours, the total amount shall not exceed 1000kg. All castings using the same heat treatment process can be regarded as one batch for inspection.
5.2.2 Under the condition of stable production (including the stability of raw materials, smelting process, test methods, inspection and other processes), the same alloy poured in different smelting heats within 8 hours of... All castings of the same heat treatment process can be inspected as one batch. 5.2.3 The same alloy cast in different smelting furnaces can be inspected as one batch if it meets the requirements of 5.2.2. Otherwise, the mechanical properties of single-cast samples need to be tested for each different smelting heat. 5.3 Sample
5.3.1 The shape and size of the single-cast sample of copper alloy castings shall comply with the provisions of Appendix A in GB1176---87. 5.3.2 The shape and size of single-cast samples of lead alloy castings shall comply with the provisions of 2.3 in GB/T1173--95. 5.3.3 The mold of the single-cast sample should use the same casting material as the casting, and should be cast in the same batch as the casting. For castings that need to be supplied after heat treatment, single cast specimens should be heat treated together with the castings. 5.3.4 If the test result is unqualified due to defects in the sample, the sample should be re-sampled for testing. If there is no spare sample, the main sample can be taken. The cutting position and size of the bulk sample shall be agreed upon by both parties. 5.3.5 The average tensile strength of the body sample should not be less than 80% of the single-cast sample, and the length rate should not be less than 50% of the single-cast sample. 5.4 Number of tests, evaluation and retesting of test results 5.4.1 The number of tests for chemical composition and mechanical properties is one set for each batch. If there are special requirements for the number of tests, they should be decided through negotiation between the supplier and the buyer.
5.4.2 Chemical composition samples are provided in a set of 2, and one sample is allowed to be tested for the first time. As long as one of them meets the requirements, the chemical composition of the batch of alloys is qualified. If the analysis results of both samples are unqualified, the chemical composition of the batch of alloys is unqualified. 5.4.3 There are three mechanical property specimens in a set, and one specimen is tested for the first time. If the measured mechanical properties meet the requirements, the mechanical properties of the batch of alloys are qualified. If the requirements are not met, two additional specimens are allowed to be used for retesting. 368
JB/T 5000.5 .. 1998
5.4.4 If both samples meet the requirements in the retest, the mechanical properties of the batch of alloys are still qualified; if there is still 1 in the retest result If the requirements are not met at all, the mechanical properties of this batch of alloys are unqualified. 5.5 Acceptance of the shape, size and surface quality of castings 5.5.1 The acceptance of the shape and size of castings shall be in accordance with the provisions of 3.6. 5.5.2 The acceptance of the surface quality of castings shall be in accordance with the provisions of 3.7. 5.6
Validity of test
Tensile test When the test results do not meet the requirements due to one of the following circumstances, the test is invalid and the test should be re-tested. The sample is improperly installed on the testing machine or the testing machine Improper operation; one sample has casting defects or the sample is improperly machined; the sample is broken outside the gauge length;
There are casting defects on the fracture surface after the sample is broken. 6 Marking and Certification
6.1 Castings that have passed the inspection shall have the qualification mark of the supplier's technical inspection department. Castings leaving the factory should be accompanied by a quality certificate signed by the supplier's technical inspection department. The certificate should include the following content: 6.2
a) Supplier's name:
b) Part number or ordering contract number;
c) Material grade;
d) Various inspection results.
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