SAND CASTING EQUIPMENT.
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Application and development of casting equipment:
1. Modeling equipment
Adopting automatic molding production line for casting production, not only can improve production efficiency and product quality, but also can improve working conditions and production environment, the effect is very obvious.
In recent years, the number of automatic molding production lines has increased rapidly, mainly with three characteristics: first, the use of automatic molding production lines are no longer limited to large backbone casting enterprises. Two foundries in Xixia, Henan province, for example, each have four or five automatic molding lines. Township enterprises that used to produce by native methods have been transformed into founders that use automatic molding production lines, but there are a number of enterprises. Now, although the casting industry of Jiangsu, Shandong, Liaoning and other provinces in coastal areas still accounts for a large proportion, a considerable number of enterprises in the central and western regions have adopted automatic molding production lines; Secondly, the domestic automatic production line has begun to supply equipment casting enterprises stably, and there are four or five manufacturers of horizontal parting automatic molding line in China. But in the whole automatic production line produced in China is still a few, and more low - grade; Thirdly, there are many automatic molding production lines, but there are still a few casting enterprises that can fully play their role in accordance with the design ability of the production line. There are not only problems that they cannot fully grasp the use of automatic molding production line, but also problems that other processes cannot effectively match the ability and tempo of the production line.
2. Core making equipment
In recent years, core-making equipment has developed rapidly from single machine operation to multi-process mechanization, and then to automatic production line. The trend of the development of core making equipment is that the degree of automation is getting higher and higher, and it is gradually developing towards the direction of using robots to work and forming automatic core making units.
In recent years, the level of core making equipment and core making technology in China''s foundry factories has been greatly improved. As for the level of top core making equipment in China alone, although there is still a distance between core making equipment and foreign core making equipment in terms of operation reliability, the gap has been greatly narrowed. At present, in addition to the robot core - making center is still the main choice of foreign equipment, the other core - making equipment basic choice of domestic manufacturers of core - making equipment products.
(1) the core equipment of major progress in recent years, has gradually developed into the core equipment of composed of single conductor or system safe, efficient, reliable and core-making unit and turnkey core project, and in the domestic first creatively will core making equipment to expand to the sand mold system, realize the precision casting sand core, and with its economy of investment and operation cost, and excellent quality to be a way of modelling of a new choice. In terms of core making, there are mainly hot core box, cold core box, self-hardening sand, shell core and various kinds of oil sand for casting production. Among them, triethylamine solidified cold core box core making process has developed most rapidly due to its characteristics of high efficiency, low consumption and high dimensional accuracy. It is a rapid curing process in which phenolic resin and isocyanate, which are used as binder, are mixed with sand at room temperature, and then injected into the core box by the core shooting machine and then passed into triethylamine. With the development of triethylamine cold core box technology, cold core box core modeling has begun to replace the coated sand shell casting, and has the inherent advantages of replacing the molding line (quality, cost, mounting speed and product modification, etc.).
(2) The existing problems and development trend of domestic core-making equipment. Compared with foreign core-making equipment, the core-making equipment produced by the vast majority of domestic manufacturers still has many problems to be improved, such as low level, high energy consumption and poor operation reliability. The core manufacturing equipment industry should develop core manufacturing equipment in line with the trend of advanced, scientific, environmental protection, low energy consumption and practical development according to the numerous foundry factories, uneven development level and specific product and process characteristics in China.
According to the current development trend, it is necessary to develop the anti-wettability and anti-casting pulse grain technology of triethylamine cold core box method in order to save the binder, reduce pollution and casting defects, and reduce the cost. Improve and improve the performance of vertical parting box-less injection molding machine and air impact molding machine, control system function, at the same time molding line auxiliary machine should be developed in accordance with the principle of generalization, serialization, improve the level of supporting; Accelerate the development of personalized and practical air flow compaction molding machine, which is suitable for complex shape or multiple varieties of mass production.
Improve the quality, technical content, technical level and supporting capacity of sand treatment equipment, fill the technical gaps including old sand cooling device and bucket elevator suitable for transporting old sand as soon as possible, and strive to improve the design level of sand treatment system; Research and development of a variety of resin self-hardening sand, good use effect, long life complete equipment, increase variety, improve performance; Focus on the development of cold core box core shooting machine series products and core sand mixing and sand feeding equipment.
In the face of fierce international market competition situation, the core equipment industry according to China''s national conditions, combining the need of actual production, combination, blaze new trails, strive to develop advanced, scientific, high efficiency, low consumption and practical, and with independent intellectual property right is the core of the new product, in order to change most of the foundry enterprises in our country the backwardness of the process technology and equipment rushes out a shortcut to low investment and quick result.
3. Smelting equipment
(1) According to incomplete statistics, there are more than 40,000 cupolas in China, among which there are more than 70% cupolas with a melting rate of 3~5t/h, about 300~350 cupolas with a melting rate of 6~9t/h (mainly 7t/h), about 200~250 cupolas with a melting rate of 10~12t/h, and less than 30 cupolas with a melting rate of 15T /h or above in China.
Cupola is the main melting equipment in China''s foundry industry because of its high melting efficiency. The development trend of cupola is high melting efficiency (melting rate > 10t/h), water-cooled long furnace life, external hot air and oxygen-enriched air supply, etc. In addition, cupola - electric furnace double melting is also being promoted.
(2) electric furnace induction furnace is a smelting equipment commonly used in foundry at present. According to the power frequency, it can be divided into three types: high frequency furnace (> 10000Hz), medium frequency furnace (50-10000hz) and power frequency furnace (50Hz). According to the purpose of the process can be divided into melting furnace, heat preservation furnace and heat treatment equipment. The commonly used induction furnace is classified as core-induction melting furnace, core-free induction melting furnace, vacuum induction melting furnace and induction quenching equipment.
At present, the adoption of intermediate frequency induction furnace smelting is very common at home and abroad, and its development direction is to improve the specific power, realize the double high and fast melting of electric efficiency and thermal efficiency; The power is continuously adjustable to meet the requirements of different heating and heat preservation conditions; Adopting frequency conversion technology; Double power supply; Dynamic management, the realization of programming jobs.
4. Energy saving and environmental protection equipment
China''s foundry industry in energy conservation and environmental protection investment is still very small, except for a few enterprises are equipped with perfect environmental protection equipment, most enterprises are not equipped with environmental protection equipment or environmental protection equipment is quite simple, foundry for environmental protection investment accounted for the entire foundry equipment investment of 5% ~ 8% (industrial developed countries generally 20% ~ 30%). The application of dust removal equipment, old sand regeneration equipment, pouring flue gas treatment equipment, charge preparation equipment and waste heat reuse equipment started late.
Production of casting equipment
There are more than 400 foundry equipment manufacturers in China, most of which are small and medium-sized enterprises, and more than 70% of them are concentrated in Shandong, Jiangsu, Shanghai, Zhejiang and Hebei provinces and cities. Since 2003, domestic static pressure automatic molding line.
The future development trend of casting equipment is large capacity, specialization, high precision, energy saving, environmental protection and low noise. Energy-saving and emission reduction equipment recommended by China Foundry Association to national Development and Reform Commission in 2008.
The import and export of casting equipment
The export of China''s casting equipment is growing rapidly, but most of the exported casting equipment is general casting equipment, while most of the imported casting equipment in the same period is key casting equipment with high technical content, and its import price is several times of the export price.
Four, conclusion
On the whole, the level of casting equipment in China is far behind that in foreign countries, and modern equipment is the hardware condition for realizing sustainable development and building environmentally friendly casting industry. Therefore, it is urgent for foundry equipment manufacturing to establish an enterprise-oriented development platform combining official, production, learning, research and application, strengthen scientific and technological innovation, and produce high-quality equipment with independent intellectual property rights, so as to improve its comprehensive competitive strength, turn danger into opportunity, and meet various challenges.
Adopting automatic molding production line for casting production, not only can improve production efficiency and product quality, but also can improve working conditions and production environment, the effect is very obvious.
In recent years, the number of automatic molding production lines has increased rapidly, mainly with three characteristics: first, the use of automatic molding production lines are no longer limited to large backbone casting enterprises. Two foundries in Xixia, Henan province, for example, each have four or five automatic molding lines. Township enterprises that used to produce by native methods have been transformed into founders that use automatic molding production lines, but there are a number of enterprises. Now, although the casting industry of Jiangsu, Shandong, Liaoning and other provinces in coastal areas still accounts for a large proportion, a considerable number of enterprises in the central and western regions have adopted automatic molding production lines; Secondly, the domestic automatic production line has begun to supply equipment casting enterprises stably, and there are four or five manufacturers of horizontal parting automatic molding line in China. But in the whole automatic production line produced in China is still a few, and more low - grade; Thirdly, there are many automatic molding production lines, but there are still a few casting enterprises that can fully play their role in accordance with the design ability of the production line. There are not only problems that they cannot fully grasp the use of automatic molding production line, but also problems that other processes cannot effectively match the ability and tempo of the production line.
2. Core making equipment
In recent years, core-making equipment has developed rapidly from single machine operation to multi-process mechanization, and then to automatic production line. The trend of the development of core making equipment is that the degree of automation is getting higher and higher, and it is gradually developing towards the direction of using robots to work and forming automatic core making units.
In recent years, the level of core making equipment and core making technology in China''s foundry factories has been greatly improved. As for the level of top core making equipment in China alone, although there is still a distance between core making equipment and foreign core making equipment in terms of operation reliability, the gap has been greatly narrowed. At present, in addition to the robot core - making center is still the main choice of foreign equipment, the other core - making equipment basic choice of domestic manufacturers of core - making equipment products.
(1) the core equipment of major progress in recent years, has gradually developed into the core equipment of composed of single conductor or system safe, efficient, reliable and core-making unit and turnkey core project, and in the domestic first creatively will core making equipment to expand to the sand mold system, realize the precision casting sand core, and with its economy of investment and operation cost, and excellent quality to be a way of modelling of a new choice. In terms of core making, there are mainly hot core box, cold core box, self-hardening sand, shell core and various kinds of oil sand for casting production. Among them, triethylamine solidified cold core box core making process has developed most rapidly due to its characteristics of high efficiency, low consumption and high dimensional accuracy. It is a rapid curing process in which phenolic resin and isocyanate, which are used as binder, are mixed with sand at room temperature, and then injected into the core box by the core shooting machine and then passed into triethylamine. With the development of triethylamine cold core box technology, cold core box core modeling has begun to replace the coated sand shell casting, and has the inherent advantages of replacing the molding line (quality, cost, mounting speed and product modification, etc.).
(2) The existing problems and development trend of domestic core-making equipment. Compared with foreign core-making equipment, the core-making equipment produced by the vast majority of domestic manufacturers still has many problems to be improved, such as low level, high energy consumption and poor operation reliability. The core manufacturing equipment industry should develop core manufacturing equipment in line with the trend of advanced, scientific, environmental protection, low energy consumption and practical development according to the numerous foundry factories, uneven development level and specific product and process characteristics in China.
According to the current development trend, it is necessary to develop the anti-wettability and anti-casting pulse grain technology of triethylamine cold core box method in order to save the binder, reduce pollution and casting defects, and reduce the cost. Improve and improve the performance of vertical parting box-less injection molding machine and air impact molding machine, control system function, at the same time molding line auxiliary machine should be developed in accordance with the principle of generalization, serialization, improve the level of supporting; Accelerate the development of personalized and practical air flow compaction molding machine, which is suitable for complex shape or multiple varieties of mass production.
Improve the quality, technical content, technical level and supporting capacity of sand treatment equipment, fill the technical gaps including old sand cooling device and bucket elevator suitable for transporting old sand as soon as possible, and strive to improve the design level of sand treatment system; Research and development of a variety of resin self-hardening sand, good use effect, long life complete equipment, increase variety, improve performance; Focus on the development of cold core box core shooting machine series products and core sand mixing and sand feeding equipment.
In the face of fierce international market competition situation, the core equipment industry according to China''s national conditions, combining the need of actual production, combination, blaze new trails, strive to develop advanced, scientific, high efficiency, low consumption and practical, and with independent intellectual property right is the core of the new product, in order to change most of the foundry enterprises in our country the backwardness of the process technology and equipment rushes out a shortcut to low investment and quick result.
3. Smelting equipment
(1) According to incomplete statistics, there are more than 40,000 cupolas in China, among which there are more than 70% cupolas with a melting rate of 3~5t/h, about 300~350 cupolas with a melting rate of 6~9t/h (mainly 7t/h), about 200~250 cupolas with a melting rate of 10~12t/h, and less than 30 cupolas with a melting rate of 15T /h or above in China.
Cupola is the main melting equipment in China''s foundry industry because of its high melting efficiency. The development trend of cupola is high melting efficiency (melting rate > 10t/h), water-cooled long furnace life, external hot air and oxygen-enriched air supply, etc. In addition, cupola - electric furnace double melting is also being promoted.
(2) electric furnace induction furnace is a smelting equipment commonly used in foundry at present. According to the power frequency, it can be divided into three types: high frequency furnace (> 10000Hz), medium frequency furnace (50-10000hz) and power frequency furnace (50Hz). According to the purpose of the process can be divided into melting furnace, heat preservation furnace and heat treatment equipment. The commonly used induction furnace is classified as core-induction melting furnace, core-free induction melting furnace, vacuum induction melting furnace and induction quenching equipment.
At present, the adoption of intermediate frequency induction furnace smelting is very common at home and abroad, and its development direction is to improve the specific power, realize the double high and fast melting of electric efficiency and thermal efficiency; The power is continuously adjustable to meet the requirements of different heating and heat preservation conditions; Adopting frequency conversion technology; Double power supply; Dynamic management, the realization of programming jobs.
4. Energy saving and environmental protection equipment
China''s foundry industry in energy conservation and environmental protection investment is still very small, except for a few enterprises are equipped with perfect environmental protection equipment, most enterprises are not equipped with environmental protection equipment or environmental protection equipment is quite simple, foundry for environmental protection investment accounted for the entire foundry equipment investment of 5% ~ 8% (industrial developed countries generally 20% ~ 30%). The application of dust removal equipment, old sand regeneration equipment, pouring flue gas treatment equipment, charge preparation equipment and waste heat reuse equipment started late.
Production of casting equipment
There are more than 400 foundry equipment manufacturers in China, most of which are small and medium-sized enterprises, and more than 70% of them are concentrated in Shandong, Jiangsu, Shanghai, Zhejiang and Hebei provinces and cities. Since 2003, domestic static pressure automatic molding line.
The future development trend of casting equipment is large capacity, specialization, high precision, energy saving, environmental protection and low noise. Energy-saving and emission reduction equipment recommended by China Foundry Association to national Development and Reform Commission in 2008.
The import and export of casting equipment
The export of China''s casting equipment is growing rapidly, but most of the exported casting equipment is general casting equipment, while most of the imported casting equipment in the same period is key casting equipment with high technical content, and its import price is several times of the export price.
Four, conclusion
On the whole, the level of casting equipment in China is far behind that in foreign countries, and modern equipment is the hardware condition for realizing sustainable development and building environmentally friendly casting industry. Therefore, it is urgent for foundry equipment manufacturing to establish an enterprise-oriented development platform combining official, production, learning, research and application, strengthen scientific and technological innovation, and produce high-quality equipment with independent intellectual property rights, so as to improve its comprehensive competitive strength, turn danger into opportunity, and meet various challenges.
