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Special explanation of cold box molding line

Special explanation of cold box molding line

The casting molding material is mainly natural silica sand. According to the ratio of iron sand to 1:1.2, the reuse rate of clay sand and organic binder sand is generally 80% to 90%, and 10% to 20% of the recycled sand should be kept constant. Abandoned; the reuse rate of sodium silicate sand is much lower, causing great damage to the environment. Compared with the traditional clay sand molding line, the new cold box coreless core molding line has irreplaceable advantages in terms of fixed asset investment, raw sand resource utilization, operation and maintenance, energy saving and emission reduction, and environmental protection. Qingdao Sanzhuji Equipment Manufacturing Co., Ltd. can customize the design of sand reclamation equipment according to the amount of old sand regeneration.


1. Process characteristics of cold core combined molding line
Using triethylamine cold core box core making process, using cold core box core shooting machine to make the upper and lower molds (or left half and right half) of the casting, and perform core lowering, core assembly, molding, and pouring. This boxless core assembly molding process is the cold core assembly molding process. The cold core composite molding process is a new type of precision sand core composite molding technology. Compared with the furan resin cold self-hardening sand molding technology and the phenolic urethane cold self-hardening sand molding technology, the size of the sand it produces More precise and stable, better quality, faster modeling speed, single machine modeling productivity can reach more than 30 moulds/h. The cold core combined moulding line can be produced independently by one unit, or can be produced by multiple units at the same time; mass production can be carried out using a mechanized and automated assembly line. The biggest feature of the cold core combined molding line is the boxless molding. Compared with various clay sand molding lines, it can save huge investment in the molding line and sand treatment workshop. Compared with other molding tools, the cold core box molding process has production High efficiency, good surface quality of castings, high dimensional accuracy of castings, low sand-to-iron ratio (up to 1:1), energy saving and emission reduction, and improved environmental protection. Cold core composite molding process application can be used to produce steel castings, ductile iron castings, alloy gray iron castings, aluminum castings, magnesium castings, etc. It is widely used in hydraulic parts, pump housings, gearbox bodies, pipe fittings, valve bodies, cylinder heads, etc. Production of castings such as cylinder blocks.


2. Cold core combined molding line system,The cold core combination molding line includes:
2.1 A fully automatic mold making (core) unit from sand supply to sand mixing to cold core box core shooter
The molding (core) unit is composed of 2 cold core box core shooting machines, which are used to produce the upper and lower molds of 1 mold, or the upper and lower molds of 2 molds, equipped with a set of core taking robots. The sand mold system is used to automatically grab the upper and lower sand molds on the core taking station of the core making machine to the discharge station on the subsequent core assembly conveyor line. Modeling productivity can reach more than 80 moulds/h. The supporting equipment uses 1 fully automatic mobile core sand mixer, 1 core sand sending system, 1 refrigerated compressed air dryer, 1 fully automatic exhaust gas treatment device, 1 compressed air storage bag, and 1 original Dust collectors and other supporting equipment for sand daily consumption. Two cold core machine mainframes and supporting equipment form an independent and complete automatic molding (core) system unit.
2.2 A step-by-step conveying line with no box assembly and core combination to realize automation of coating, drying and forming
Core assembly lines for simple and moderately complex castings: According to the productivity of the cold box core making machine and the surface drying furnace, two stepping automatic roller core assembly lines are established. Each conveying line corresponds to a molding machine, and a straight water-based paint spraying station is established on each conveying line, and a hot air circulating continuous surface drying furnace is installed on each line. Each line is equipped with a core setting station and a conveying station. The sand core is lowered into the lower mold. The two lines share a set of robot system, which will grab and close the upper mold to the lower mold in sequence, and then close the mold. The latter group is transferred to the next pouring line for vertical pouring or flat pouring. Core assembly line for complex castings such as cylinder heads: Establish a step-by-step automatic roller core assembly conveyor line, set up the upper mold, lower mold, intake duct, exhaust duct, upper water jacket, lower water jacket and other core lowering stations and the conveying station, put the sand core into the lower mold, the dipping robot grabs the lower core set and the upper mold together, and puts the dipped sand core set into the surface drying oven for surface drying of the paint. A set of type-fitting robot system sequentially grabs and fits the upper type to the lower type, and transfers the combined type group to the next pouring line for vertical pouring or flat pouring.
2.3 A set of pouring cooling cycle line system to realize automatic cooling and sand falling of castings
It is composed of 1 pouring line, 3 cooling lines, 2 transfer car systems, 1 set of combined manipulator and sand transfer trolley. The pouring and cooling lines are respectively used for pouring and cooling sand castings. The transfer vehicle system B realizes the transfer of the sand mold transfer trolleys that have been poured on the pouring line to three cooling lines respectively; the transfer vehicle system A cooperates with the molding robot and the molding line manipulator to realize the sand mold combination and sand mold group transportation and transfer . The moulding line manipulator can transfer the cooled sand moulds and castings to the shakeout machine, as well as tighten the bolts on the transfer trolley at the moulding station to lock the sand mould group
2.4 A set of cold core sand mechanical method (or thermal method) regeneration system realizes the regeneration and reuse of molding sand and core sand resin sand, avoiding the waste of old sand and environmental pollution, and reducing the production and operation cost of the molding line. Establish a set of molding sand thermal regeneration system to realize the regeneration and reuse of molding sand and core sand, avoid waste of old sand and environmental pollution, and realize economic benefits for the factory.


3. The superiority of cold core combination molding line
The modern cold box process molding line is superior to the traditional clay sand molding line in terms of investment cost, production and operation cost, environmental protection and casting quality. Therefore, it is being used by more and more foundry companies to replace clay sand molding lines and metals. Type (gravity casting, low pressure casting, etc.) casting line.
3.1 Saving of investment cost
According to conventional statistics, the investment of a cold-core combined molding line is usually 30% to 40% of that of the clay sand molding line. Because in the clay sand molding, there is a complex clay sand molding line system and a huge sand processing workshop; while the cold core combined molding line only has a simple automatic production line, and the cost of sand, resin, amine supply equipment system Very low, so the total investment cost is relatively low.
3.2 Effective use of investment costs
The production capacity of the clay sand moulding line is generally 60~120 moulds/h, but in actual production, the designed production capacity is usually not reached; or the production line is not fully efficient due to insufficient production tasks, that is, the effective use of investment costs low. The cold core combined molding line can be independently produced by 1 unit. First, build a cold core box core shooting machine for molding; the productivity can reach ≥ 30 moulds/h, and then another cold core machine can be built; the productivity can reach ≥ 60 moulds, According to the needs of production, enough molding units can be added at any time to meet production. Therefore, the cold core combined molding line has flexible construction properties and flexible production methods, and investment costs can be effectively utilized.
3.3 Production and operation costs
Operating cost of raw and auxiliary materials for production: Compared with the clay sand molding line, the total operating cost of the raw and auxiliary materials for production is roughly the same, and even slightly higher than the operating cost of the clay sand molding line. Although the molding sand used in the cold core combined molding process has undergone sand regeneration treatment, the sand recycling rate has reached 95%, and the resin addition can be reduced to 1%, which greatly reduces the production and operation costs. The direct cost of auxiliary materials is still lower than the direct cost of raw and auxiliary materials of the cold box shape Ding Yi. However, when the clay sand molding line produces castings, the resin core sand is mixed into the clay sand system. Not only does it need to increase clay and organic additives (such as coal powder), it is more important to maintain the balance of the entire molding sand system. The same amount of good clay sand is removed from the system. The more core sand, the greater the cost. In particular, the bottom surface of complex castings such as cylinder blocks and heads are often formed with external "cores", and clay sand modeling becomes a very expensive production and operation system. Therefore, the operation cost of sand treatment of clay sand offsets the direct cost difference of raw and auxiliary materials. The operating cost of the equipment system: due to the complexity of the clay sand molding line system and the sand processing system, the equipment maintenance cost and energy consumption cost are very high, usually accounting for about 10% of the total operating cost each year. The equipment maintenance cost and energy consumption cost of the cold box core molding line are usually 30%-40% of the clay sand molding line.
3.4 Energy saving and emission reduction costs
Energy cost: As the cold core combined molding line is simpler than the clay sand molding line, the sand treatment is only to mix the liquid resin and the original sand evenly, and the resin sand molding sand is mechanically (or thermally) regenerated, and each ton of sand is consumed and discharged The energy is about 25% of the clay sand molding line. The general sand to iron ratio of the clay sand molding line is 7:1, and the general sand to iron ratio of the cold core box molding line is 1.5:1, and the required sand is 4.5 times different. Therefore, the total energy cost of the cold core box molding line is clay sand molding 5.5% of the line energy cost.
Waste discharge: After the molding sand of the cold core box assembly core molding line is mechanically or thermally regenerated, the recycling rate of molding sand and core sand can reach 95%; while the clay sand molding line generally must be the same amount due to the mixing of core sand The good clay sand is removed from the system, and the discharge of this waste sand is quite amazing. This means that on the one hand, the foundry needs to purchase a large amount of new sand every day for core making, on the other hand, it also needs to spend waste sand transportation fees and waste sand disposal environmental protection fees. Therefore, the waste discharge cost of clay sand is much higher than the waste discharge cost of the cold box core molding line.
3.5 Technical advantages
The process nature of the cold box molding line determines that the cold box molding has the technical advantages of providing more accurate dimensions, more stable cavity, smaller machining allowance, better casting surface quality, etc., which will save subsequent machinery Processing costs, reducing the cost of casting blanks, and increasing the value of castings are all very obvious.


Qingdao sanzhuji is a sand casting equipment manufacturer with a history of 11 years. It has a professional engineer and production team, and can customize sand mixer, molding machine, sand reclamation equipment, dust collector, shot blasting machine according to requirements. Guests are welcome Visit the factory area.

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