鑄造灰口鑄鐵工具機鑄件智慧化熔解製程之建立

灰口鑄鐵是一重要的傳統鑄造材料，灰口鑄鐵件不論是在設計、材質規範、熔解澆鑄、機械加工及品質管控等方面都有非常豐富的資訊可以參考。但是單單就熔解與澆鑄這一部份而言，所涉及的製程是相當複雜的，嚴謹的製程管理是鑄造品質與競爭力的重要保證。而智慧化熔解製程是澆鑄灰口鑄鐵鑄件極為重要的一個環節，也是極需發展的一項新的技術。其成份設定、配料選用、熔解溫度、澆鑄溫度、鐵水品質、材質的預測與驗證是一系列息息相關的程序。將熔解製程智慧化，應是鑄造製程智慧化的一項基礎工程。鑄鐵熱分析技術的原理及商業產品已發展多年，本研究嘗試將其用之於工具機鑄件的熔解過程，就成份確定、鐵水成核能力及機械性質等做基礎的分析及驗證，而應用熱分析曲線上的特性參數溫度與預測計算公式，對於灰口鑄鐵硬度與抗拉強度的預測準確性高且具可行性；而在預測抗拉強度時，依實際製程控制所得到的實測值結果，必須達到最初預測值設定時的最低抗拉強度的要求，如此預測的結果才會準確。

關鍵字

智慧熔解；灰口鑄鐵；熱分析

並列摘要

Gray cast iron is an important traditional casting material. In literature ample information has been available for grey cast iron regarding casting design alloy specification melting and casting, machinability, quality control, etc. However, in melting and casting alone, the process variable involved are quite complicate, and strict control is the required to attain good quality. The smart melting process not only plays an important role in the production of gray iron castings, but also is the most important part. Composition setting, charge make-up, melting and casting temperatures, molten iron quality, material properties prediction and verification are important parameters and are also closely related. The smart melting process should be the basis for the intelligentization of the casting process. The thermal analysis technology of cast iron has been developed for many years. This research attempts to employ the thermal analysis technology in the melting process to analysis and predict the melt compositions, the nucleation of ability graphitization and mechanical properties. The results show that the prediction of the hardness and tensile strength of gray cast iron are relatively accurate.