Vanishing mold casting is called EPC, also known as vaporized mold casting or solid casting. It is the use of foam mold sample instead of ordinary mold modeling tightly, after the mold is made without taking out the mold, directly into the metal liquid, in the role of high-temperature metal liquid, foam mold sample heat vaporization, combustion and disappearance, the metal liquid to replace the original foam mold occupies the space position, cooling and solidification is to obtain the required castings.
sanzhuji combined with the characteristics of disappearing mold casting equipment and fusion sand casting production process, made the following summary
1、disappearing mold casting production line process is divided into two major parts of the white zone and black zone.
1.1 white zone process: First, according to the casting material and wall thickness to choose the original beads suitable for it. The original beads will be added into the intermittent hairdresser for pre-foaming according to the quantity, so that it can reach the density required by the process, and then sent to the maturation bin for maturation after drying in the vulcanization bed of the hairdresser. After maturing, the beads are transported to the molding room, and the beads are injected into the mold on the molding machine, which will be swollen and melted by steam to form the casting mold, and cooled down by cold water to make the white mold have the same strength, then the molding machine starts to take out the white mold manually and put it into the white mold drying car, and transported to the hot air tunnel through the drying room for drying. White mold drying car in the drying room track walking, each advance indoor a car, in the other end of the top out a car, so the cycle. The drying room adopts hot air forced circulation system, and the temperature and humidity inside the drying room are automatically controlled by PLC to meet the process requirements, which greatly improves the production efficiency and saves energy. After drying, the white mold is transported to the mold assembly room to assemble and bond the sprue. The assembled white mold is transported to the coating room for dipping and painting. Different coating formulas are selected for different materials of castings, and the raw materials are put into the coating mixer for stirring, and the coating density is tested after reaching the time required by the process, and then put into the coating tank for workers to use after passing the test. The dip-painted white mold is put into the drying car and transported to the yellow mold drying room for drying, and the dried yellow mold is transported to the secondary coating room for second dip-painting to reach the coating thickness required by the process, and then transported to the yellow mold drying room for drying and repairing. After the second drying, the yellow mold is transported to the modeling department of the black zone for filling and modeling with the drying truck, and the empty truck returns to the molding room. So far the process of white area is finished.
1.2 Black zone process flow.
1.21 Moulding Department: The moulding department is composed of two moulding lines and one box return line. The cycle operation of sand box is completed by sand box track and manual variable rail car, each production line is composed of the number of sand boxes required by the process. Each molding line is composed of one 2-ton single-dimensional vibrating table and two 4-ton frequency-controlled three-dimensional vibrating tables. The moulded sand boxes enter the two pouring and cooling lines in turn, and the pouring and cooling lines consist of vacuum docking machines. After a certain number of sand boxes enter the pouring cooling line, the vacuum docking machine automatically docks and pours manually. After the pouring is finished, the vacuum docking machine will be reset and the vacuum will be withdrawn. At the same time of pouring in these two pouring lines, the sand box made by the moulding line enters the two pouring lines in turn, and repeats the action of the first two pouring lines, and so on.
This molding department adopts BSZ-04k frequency three-dimensional vibrating table, its structure and working principle.
Three pairs of 6 vibration motors are used as the vibration source. Each pair of excitation motor reverse synchronous operation, respectively, the formation of three directions (X, Y, Z) of the combined force, so that the vibration table and its above the sand box with a certain acceleration vibration, to complete the sand box in the dry sand compact. The vibrating table is supported by air spring and can be lifted, which makes the sand box more stable in the process of vibrating and prevents the sand from extruding the white mold from changing shape. In addition, the vibrating table is equipped with pneumatic automatic clamping device. It realizes the operation needs of fast, convenient and flexible operation of the sand box and the compacting table fastened together.
1.22 Vacuum negative pressure system: Vacuum system is the main equipment of disappearing mold casting process, its role is to create a stable negative pressure field for the negative pressure sand box, so that the dry sand under the action of atmospheric pressure to achieve a certain degree of compactness, while the foam model gasification process generated by the gas and dust particles and other foreign matter sucked away, to ensure that the pouring smooth and orderly.
This vacuum system consists of two 2BE water ring vacuum pumps, dust filter, pressure stabilizing tank, water tank, vacuum docking machine, etc. The 2BE water ring vacuum pump is a localization of German technology, with stable performance and high efficiency and energy saving. The working process of this machine is, firstly, the exhaust gas in the sand box is pumped to the wet dust collector, and the purified exhaust gas filtered by the dust collector enters into the stabilizing tank (the stabilizing tank plays the role of stabilizing the negative pressure to prevent the negative pressure value from fluctuating excessively to the negative pressure value of the sand box), the stabilizing tank is connected with the water ring vacuum pump, and the exhaust gas is pumped into the vacuum pump from the stabilizing tank and then sent to the gas-water separator, and the exhaust gas separated by the gas-water is The exhaust gas will be discharged into the atmosphere, and the separated water will be recycled. The hydraulic flip box of this system can realize the automatic sand drop function of the sand box and reduce the labor intensity of workers.
1.23 Sand processing system: After pouring and cooling, the castings are transported to the box return line with the sand box by manual railcar, and the sand box is manually pushed to the hydraulic box turning machine for turning, and the castings fall on the sand falling grate after turning and are transported to the casting cleaning department for the next process. At this time, the hot dry sand flows evenly into the vibrating conveyor sieving machine through the sand drop bucket, and after sieving, the impurities in the sand, sand lumps, large iron bean flying edge, etc. flow into the waste bucket. Because of the high temperature of the falling sand, the sieve plate is specially made of stainless steel plate. The hot sand is lifted by the high temperature resistant ring chain elevator into the wind separator and magnetic separator for the separation of wind and magnetic separation. The dust enters the dust removal system from the dust removal port of the wind separator; magnetic materials such as iron beans are separated by magnetic separation and fall into the waste bin. This equipment is the localization of German products. The hot sand after wind and magnetic separation flows evenly into the boiling cooling bed. The hot sand is blown up by high pressure air in the boiling bed, tumbles and boils continuously into a fluid state and moves forward, repeatedly contacting with the water cooling tube for heat exchange, until it flows into the bucket elevator from the sand outlet at the end of the boiling bed. At the same time the hot sand and room temperature air heat exchange, in this process the dust in the sand with the hot air into the dust removal system. The best sand cooling equipment in the world and at home for vanishing mould casting and "V" method casting today. The cooled dry sand is lifted by the bucket elevator and sent to the intermediate sand storage.
2、The role of intermediate sand storage.
2.1 Store a large amount of spare sand, so that the whole line of molding sand has been in the closed line of recycling, in order to improve the operating environment of workers.
2.2 Buffer transfer sand quantity. When the production process needs to drop sand, pour box without filling box vibration solid modeling, or vice versa, that is, when sand drop and modeling do not need to work simultaneously, the setting of intermediate buffer sand bucket can guarantee the realization of this requirement. The dry sand from the intermediate sand storage enters the linear vibrating sifter through the automatic sand filling door.
Qingdao Sanzhuji Equipment Manufacturing Co., Ltd. specializes in the production of sand reclamation equipment, Sand casting equipment, GS high efficiency rotary mixer, no-bake resin sand mixer, Jolt squeeze molding machine/Jolt-squeezing moulding machines, Multi- Piston Moulding Machine/Hydraulic multi-piston moulding machine,foundry molding machine, flaskless moulding machine, shot blasting machine, dust collector, according to the amount of old sand recovered Carry out plan customization, and provide sand reclamation equipment installation, commissioning, and training. Welcome guests to visit the factory.
