Description
1)casting technology
1.1）typical castings ：
1.2）Vertical modelling：（The best casting process for thin-walled board castings）
Advantages: strong filling ability, sequential solidification, high static pressure, compact casting structure, no deformation; Wide casting temperature, less sand,Epidermis hard, but very shallow white mouth depth; No error box, yield more than 97%.Disadvantages: high pouring temperature, will produce upper sticky sand; Large proportion of sprue.
1.3）Rules for sprue design Large plate：Two vertical runner (+ riser) + horizontal runner = plate castings in the middle. Microplates：2 symmetrical, 1 vertical runner (+ riser) + horizontal runner = plate castings on both sides
1.4）Optimum mold size：
1000（H） x 1000 （W）
Effective cavity area：1000（H） x 1000 （The top runner）
1.5）Single sand type size：
1000 x 1000 x （170 — 210） mm average 180mm
Casting parts = 25 Kg liquid iron =30 kg；
And and iron ratio：9.6 ：1 （= 1 x 1 x 0.18 x 1.6 / 0.030)
1.6）Molding line and sand treatment：
Adopted: A. Double-station automatic vertical parting box-less injection molding machine, double-line box-out structure:
A1. Molding machine speed enough; With melting capacity as the center, sand processing equipment.
A2. Molding machine speed (capacity) selection:
According to the design modeling ability: 24s/pcs
Modelling speed： 120pcs /h（=3600s/ 20s/pcs）production cycle balancing
A3 production cycle balancing：
1）According to 1.5T furnace count，2 furnace comes out alternately，2.05t/h./30kg=68pcs
2）Modelling 40min produce 80 pcs ，Pouring should be finished within 15 minutes.
A4 Length of molding cooling line:
Ensure the cooling time of each pcs is 45-60 minutes.，
= 80pcs（40min）+ 15min（pouring）
80 x0.18 /2= 7.2 M
Each casting cooling channel is designed at 7.2 M(8 M).
A5 pouring Ladle and liquid iron ladle：
Each pcs（casting part 25Kg）liquid iron =30 kg；
Sand and iron ratio：9.6 ：1 = ( 1 x 0.10 x 0.18 x 1.6 : 0.030)
2 persons pouring, each person pouring 34pcs; Casting time for each mold: 12 seconds; need time: 13 minutes;
2peope can pouring 68pcs（=2050kg/30kg)
Pouring ladle and liquid ladle：1200（=40 x 30 ) kg /set （ according to 1.5TPouring ladle and liquid ladle design ）
A6. if use：1set 1500 kVA electric furnace transformer，1.5 T melting furnace supplies liquid iron
Iron supply efficiency = 1500 / 570 (kw.T/H) X 0.97 X0.8 = 2.05 t/H
Each 40min supply one furnace liquid iron capacity： 1.367t （ =2.05 x 40/60 )
2set furnace comes out alternately= 1200 kg liquid iron / 40min.
The liquid iron supply capacity can meet the production beat
A8 . liquid iron supply capacity ：
Use 1set 1500 kVA1500 kVA electric furnace transformer，1.5 T melting furnace
The production efficiency of each furnace = 1500 / 570 (kw.T/H) X 0.97 X0.8 = 2.05 t/H
2set furnace；can easily realize：1200/ kg liquid iron / 40min
Each day furnace working 20 hours（ = 30 furnace = 30 x 1200 kg ）= 36 T liquid iron;
Can produce 27.6 T qualified castings =（36 x 25/30 x（1-5%（iron loss））x97%(rate of finished products）
Casting iron ratio =76.8% （ 27.6/ 36)
A9. Automatic molten iron control system：Hefei university of technology double hair information system technology co. LTD
（international standard）
A10.Sand treatment system configuration
Sand volume of each mold ：1 .0 x 1.0 x 0.18 = 0.18 M³
The density of mold：1.6t/m³
production rate：120pcs/h
Amount of sand per hour： 34 T/H =0.18 x 1.6 x 120
Considering actual capabilities according to design capabilities 85-75%。（ 34/ 85 % = 40）40T/H
High speed rotor type sand mixer( 40T/H )
A11.Modeling automatic line sand treatment supporting manufacturers
Qingdao shenghong xinyuan machinery co. LTD
1.7）surface cleaning：
Adopt through going shot blasting machine
