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Key points of chip molding vibration process forming
Publish Time：
2022-12-13 10:03
Core mold vibration technology involves vertically placing inner and outer molds on a bottom tray in a pit. The hardened concrete inside the tube mold is subjected to strong vibrational force from a high-frequency vibrator in the inner mold, liquefying the concrete mixture, filling the tube mold and expelling air, gradually compacting it. A forming ring is installed at the top of the tube, and it is gently rolled and compacted using hydraulic pressure. Core mold vibration technology is used in pipe manufacturing, allowing the concrete to be compacted and formed under strong vibration.
Core mold vibration technology involves vertically placing inner and outer molds on a bottom tray in a pit. The hardened concrete within the tube mold is subjected to strong vibrational force from a high-frequency vibrator in the inner mold, liquefying the concrete mixture, filling the tube mold and expelling air, gradually achieving compaction. The top of the tube is fitted with a forming ring, which is gently rolled and compacted using hydraulic pressure. Core mold vibration technology is used in pipe manufacturing, allowing the concrete to compact and form under strong vibration.
In principle, the core mold vibration process only requires one set of tube molds to produce products of one or more specifications and varieties, so the uniformity of product dimensions is very high, and the processing quality of the steel mold is even more important. Core mold vibration—steel mold design has its special importance, and the following should be noted:
1. If the inclination angle of the socket working surface is small, when the rolling disc is lifted, because the concrete has not yet gained strength, under the action of friction, a ring crack is likely to appear at the step of the socket working surface. The number and position of reinforcing bars should be reasonable, and the vibration transmission efficiency should be high. Core mold vibration—the steel plate strength and tube mold stiffness should meet the requirements, the dimensions should be accurate, and the joints of the tube mold should be leak-proof. The surface of the steel should be smooth, the welds should be ground smooth, and there should be no hammer dents inside the cylinder. Reduce adhesion resistance, reduce the load on lifting machinery and equipment, and prevent concrete cracking in the pipe body.
2. Ensure the length, weld points, and outer diameter weld points of the steel skeleton longitudinal bars are firm. If the weld points of the skeleton are opened during the forming process, the steel bars will rebound after demolding, causing cracks in the pipe body concrete. The outer diameter of the steel bar locator should be 2~5 mm smaller than the inner diameter of the outer mold; otherwise, the steel bar skeleton after demolding will also cause cracks in the pipe body concrete due to rebound. When pressing the top, if the longitudinal bars are too long, they will bend under pressure, causing deformation of the steel bar skeleton, which is the main cause of end ring cracks. A 25mm thick concrete protective layer should be used at the top.
3. According to the pipe specifications and vibration parameters, the start time should be after the material has been fed to a certain height or after 500mm. Dry vibration, equipment idling vibration, high noise, easy damage to the vibrator and tube mold. If vibration is started too late, the gas in the lower layer concrete mixture is difficult to discharge, leaving more air bubbles and pits on the pipe wall, reducing density.
4. Core mold vibration—material feeding and vibration forming: In the vibration forming process of pipe material feeding, a rotating belt feeder is used for feeding, and vibration and feeding need to be coordinated. Adjust the feeding speed and quantity while adjusting the vibration parameters according to the production pipe specifications.
5. Core mold vibration—pipe mouth rolling and friction forming: (1) The oxide skin on the upper socket working surface is completed through the rolling process. The purpose of grinding is to smooth the concrete surface at the top, making the concrete distribution on the forming mouth working surface uniform. Under the action of pressurized vibration, the required working surface shape is formed through molding. (2) During the entire process of socket forming, high-frequency vibration should be maintained to ensure the vibration density of the concrete. (3) Rolling is based on vibration. The top is subjected to short-term vibration, and additional rolling pressure is required during vibration. During operation, the pressure should be slowly and gradually increased to avoid "crushing", making it difficult to form the socket surface. Avoid the circumferential steel bars from being pressed and sinking. (4) Generally, the rolling pressure should be controlled at 0.1 MPa. If the rolling pressure is too large, the longitudinal steel bars will bend under pressure, and the steel bars will rebound after the pressure is removed, causing circumferential cracks in the upper end of the pipe body.
Die vibration
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