1. Vertical parting and unboxing molding line is suitable for small and medium-sized castings without sand cores
Due to the high efficiency and low investment characteristics of vertical lines, for small and medium-sized castings without sand cores, we should choose vertical lines, but at the same time, we should consider several points:
(1) For disk castings with high dynamic balance requirements, vertical lines are often not suitable due to the upper and lower specific gravity segregation caused by vertical parting.
(2) The pouring system of vertical lines is different from horizontal molding lines.
(3) For castings with deep built-in cores, attention should be paid to whether the strength of the suspension with built-in cores is sufficient.
(4) For ductile iron castings with complex and special structures, it is often difficult to set the riser.
(5) The horizontal parting and unboxing molding line is suitable for all small and medium-sized castings, especially those with sand cores.
(6) It is generally not recommended to use horizontal parting box molding lines to produce medium and small castings, not only because of high investment, but also because of high operating costs, multiple failure points, and high casting costs.
The quality and management level of the sand treatment system determine the success or failure of the automated casting workshop
In reality, too many casting manufacturers, due to factors such as neglecting and neglecting the design and investment of sand treatment systems in the construction of automated casting workshops, as well as improper selection of molding materials, result in unstable and difficult to control molding sand quality, resulting in low molding line startup rate, high casting scrap rate, and poor quality.
Sand temperature control, mud content control, quantitative control, the quality of the main sand treatment equipment itself, and the quality of raw and auxiliary materials are the key factors to ensure the performance of molding sand.
3. Matching of melting capacity and automated molding line
The automated casting workshop is different from traditional casting workshops in that molding and pouring are carried out simultaneously. So the following principles need to be followed:
(1) Multiple small electric furnaces are used for differential melting and pouring.
The demand for molten iron per unit time in the automation line for small and medium-sized castings is about 2-3 tons. It is recommended to choose 3-4 electric furnaces with a capacity of 1-1.5t/h, and open one every 20 minutes to achieve differential melting and pouring, ensuring continuous supply of molten iron and meeting the needs of the production line.
(2) To ensure that the molding line does not stop, the principle for selecting the melting capacity is: melting amount=the demand for molten iron per unit time of the molding line × 1.2。
4. "Pouring level" is an indispensable link in automated casting workshops
Priority should be given to using automatic pouring machines in automated casting workshops; But domestic automatic pouring machines are still in the growth stage, and the prices of foreign automatic pouring machines are surprisingly high! In cases where economic capacity is limited, it is recommended to use a double ball track four roller circular casting line; At the same time, the pouring ladle should not be large, and it is advisable to choose a pouring ladle of 100-150kg. Many manufacturers choose ordinary I-steel ring rail structures, but the disadvantages are:
(1) The roller does not roll on a linear cold drawn round steel, but rather on a flat surface, with high resistance and inconvenient movement of the pouring ladle.
(2) There are no ball beads on the side of the pouring ladle suspension trolley, and the pouring ladle sways unstably left and right.
(3) The two roller structure is prone to causing the ladle to sway back and forth, while the four roller structure truly solves the stability of the ladle during pouring and movement.
(4) The double ball track and four roller circular pouring line can meet the requirements of smooth pouring, accurate pouring, smooth movement, and continuous pouring along the line.
Many manufacturers have caused splashing of molten iron, interruption of pouring, inability to follow pouring, and inability to collect the package due to poor pouring level. The labor intensity of workers is high, and the scrap rate of castings is high. The root cause is the unreasonable pouring ring rail structure or improper selection of pouring packages.