Self-hardening resin sand casting process details explained(3)
5、resin sand casting cost reduction and efficiency of the most important three aspects: to reduce the cost of resin sand casting, can be considered from several aspects such as equipment, raw materials, production process.
5.1 choose the appropriate self-hardening resin sand production equipment is to reduce the cost of resin sand casting premise in the choice of resin sand production equipment, not only to consider the actual situation of the enterprise, choose the appropriate price of the equipment, but also should consider the operating costs of equipment, the main should consider the following.
(1) to pay attention to the choice of dust removal equipment in the choice of production equipment, most enterprises tend to pay more attention to the quality of sand mixing equipment and regeneration equipment, while ignoring the quality of dust removal equipment. In fact, the dust removal equipment is good or bad, directly affects the quality and cost of recycled sand, if the dust removal equipment is not good, not only affects the working environment, pollution of the air, more importantly, affects the micro powder content of recycled sand, the direct result is to lead to increased production costs due to the increase in the amount of resin added when mixing sand.
(2) to consider the reliability of the equipment and its maintenance fee equipment manufacturer''s processing means, assembly level and equipment configuration level determines the reliability of its production equipment, if the reliability of the equipment is poor, the probability of equipment failure is large, the number of times to replace equipment parts increases, the utilization rate of the equipment is reduced, so that not only increases the workload of maintenance workers, increase the maintenance fee of equipment, but also lowered the production efficiency and increased production costs.
(3) To consider the energy consumption of equipment in the premise of meeting the process requirements, try to reduce the installed capacity, avoid the phenomenon of large horse-drawn car, make full use of inherent resources, reduce unnecessary energy waste, achieve the full load of equipment utilization and maximize energy utilization, increase corporate efficiency and social benefits.
5.2 The development of a correct and reasonable production process is the key to reducing the cost of resin sand casting production process is developed reasonably or not, directly affects the yield of the casting, casting quality and casting costs, in the development of the production process, the main should determine the following.
(1) determine the appropriate LOI value of the recycled sand
LOI value, that is, burn reduction is an important indicator to measure the rate of regenerated sand decontamination, but also with the amount of sand gassing and castings produce porosity class defects closely related to the indicators, cast iron parts are generally produced using furan resin sand, practice has proved that LOI value control at about 3% can fully meet production requirements, while some enterprises require LOI value control at 2.5% or less, to achieve this purpose, it is necessary to increase the Equipment, or increase the number of sand regeneration, or add more new sand, which will undoubtedly increase the investment in equipment and regeneration costs and raw material costs. Our company in the production process, gradually relax the LOI value control index from about 3% to about 4%, due to the process and proper management, and did not affect the quality index of the castings because of the change of LOI value.
(2) Determine the appropriate casting process parameters
Determine the appropriate final strength generally, resin sand mixed, after about 24 hours of self-hardening, it can reach the highest strength that is the final strength. Due to the different production conditions and production scale of each enterprise, the time interval between molding and pouring is not necessarily more than 24 hours, so the final strength should be determined by the enterprise. Smaller scale, the implementation of a few days a furnace system of enterprises, can be used 24 hours final strength standards; casting curing time does not exceed the 24 hours of enterprises, the strength reached before pouring as the final strength standards. At the same time, in production to overcome the tendency of two aspects: on the one hand, to ensure the quality and blindly improve the strength, so that the casting cost increases, resulting in waste; on the other hand is to protect the cost and depress the strength, resulting in unstable quality, fluctuations in the range, so that the quality of castings by raw materials and the operator''s influence is greater. Each enterprise should determine the appropriate final strength according to their own situation, so as to achieve maximum savings in resin and curing agent under the premise of ensuring the quality of the casting, reduce casting costs.
(3) Determine the appropriate sand-iron ratio of self-hardening resin sand because of its high strength, curing after starting the mold, the parting surface is flat, so its sand eating amount is smaller than that of clay sand, but its sand-iron ratio also has certain requirements. If the casting sand-iron ratio is too high, the production process will waste resin and curing agent and produce a large block of waste sand, which will increase the burden on the regenerator, reduce the release rate, increase the LOI value, and increase the possibility of pores in the casting; if the sand-iron ratio is too low, it is easy to produce a runner when pouring, and the casting is easy to produce deformation. According to our experience, the sand-iron ratio should be selected as 2.2~3:1.
(4) determine the appropriate modeling process casting yield rate, directly affects the casting cost, the appropriate modeling process can not only ensure the quality of castings, but also reduce casting costs, reduce the casting scrap rate is one of the most obvious and direct measures to reduce casting costs. In determining the molding process, try to make special sand box, box wall more air holes, the model to do the actual sample, using the template modeling, pouring system using ceramic tubes, internal sprue to take more and disperse, paint coating evenly, do not leak coating, set up more air bubble, to ensure that the core exhaust smoothly.
5.3 The correct choice of raw materials is the basis for reducing the cost of resin sand casting. The choice of raw materials has a greater impact on the casting cost, which has been recognized by the vast majority of peers, because the raw materials are good or bad, on the one hand, affects the amount of various materials added and consumed, on the other hand, affects the quality of the casting index.
(1) the choice of raw sand
The original sand is divided into ordinary sand, washed sand, scrub sand and other types, due to scrubbing sand in the mud content has been very little, so it can greatly reduce the waste of resin, should be preferred, followed by washed sand, but never use the original sand without treatment. The price of scrubbing sand itself is not high, generally 50 yuan / t to 70 yuan / t, but its freight is high, such as our company to buy a sand factory in Dalin scrubbing sand for 65 yuan / t, but transported to the company, the total cost of 280 yuan / t. When choosing the type of sand, one should follow the principle of choosing the nearest, so that on the one hand can reduce the expensive freight, on the other hand, to protect the supply, does not affect production. Secondly, we should try to use the raw sand with low angular coefficient. At the same time, due to the scrub sand production enterprises of the technical level and equipment equipment level is different, the quality of its production of scrub sand is also different, therefore, if there are conditions, in determining the use of sand, scrub sand production enterprises should be inspected to examine its technical condition, equipment condition and sand source condition, etc., and find each other from the sand quality control results. In short, in the process of selecting the original sand, it is best to make reference to other aspects of the problem by means of experimental comparison, to ensure production and quality under the premise that the production cost is reduced to a minimum.
(2) The choice of resin
The price of resin is expensive, generally in the 10000 yuan / t or so, so it has a greater impact on the cost of casting, while the quality of the resin produced varies greatly due to the uneven production equipment of manufacturers. If you choose a poor quality resin, not only affect the quality of the sand, resulting in increased casting scrap, but also increase the amount of resin added, the direct result is to increase the cost of casting, so the choice of raw materials, not only according to the technical data provided by the manufacturer to determine, but should be the manufacturer''s production equipment, production process and quality control means to understand, and try to carry out their own indicators of the resin We should try our best to inspect the indicators of the resin or ask the relevant inspection department with good reputation to carry out the inspection, or draw on the experience of similar manufacturers, or choose the products of well-known large enterprises with good reputation. Our company has been using the resin produced by Jinan Shengquan Group since the beginning of production. Because of its better quality and stable performance, although its price is higher than that of some enterprises, its actual production cost is not high due to its lesser amount of addition and stable production process.
(3) The choice of other raw materials
Other raw materials, including curing agent, paint, binder, release agent, sealing clay bar, etc., these raw materials on the quality of the casting is not the main impact, but the impact on the cost of casting can not be ignored, such as the amount of curing agent added to the different, not only due to the impact of molding process productivity and affect the production cost, but also affect the cost of materials. Therefore, the choice of other raw materials principle is to consider both its quality, but also to consider its match with the main materials such as procurement, transportation and other issues. In short, as long as the equipment selection is reasonable, reliable performance, normal operation, matching raw material selection, stable quality, timely supply, reasonable production process parameters, tooling apparatus to ensure that the self-hardening resin sand casting can control and reduce the casting costs, bringing development and benefits to enterprises.
Qingdao Sanzhuji Equipment Manufacturing Co., Ltd. specializes in the production of Green Sand Molding Line,Self-hardening sand molding line,foundry machines,Sand molding machine,Sand casting equipment,sand mixer,GS high efficiency rotary mixer,Resin sand mixer,no-bake resin sand mixer,Jolt squeeze molding machine/Jolt-squeezing moulding machines,Multi- Piston Moulding Machine/Hydraulic multi-piston moulding machine,sand casting molding machine,sand reclamation equipment，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.
5.1 choose the appropriate self-hardening resin sand production equipment is to reduce the cost of resin sand casting premise in the choice of resin sand production equipment, not only to consider the actual situation of the enterprise, choose the appropriate price of the equipment, but also should consider the operating costs of equipment, the main should consider the following.
(1) to pay attention to the choice of dust removal equipment in the choice of production equipment, most enterprises tend to pay more attention to the quality of sand mixing equipment and regeneration equipment, while ignoring the quality of dust removal equipment. In fact, the dust removal equipment is good or bad, directly affects the quality and cost of recycled sand, if the dust removal equipment is not good, not only affects the working environment, pollution of the air, more importantly, affects the micro powder content of recycled sand, the direct result is to lead to increased production costs due to the increase in the amount of resin added when mixing sand.
(2) to consider the reliability of the equipment and its maintenance fee equipment manufacturer''s processing means, assembly level and equipment configuration level determines the reliability of its production equipment, if the reliability of the equipment is poor, the probability of equipment failure is large, the number of times to replace equipment parts increases, the utilization rate of the equipment is reduced, so that not only increases the workload of maintenance workers, increase the maintenance fee of equipment, but also lowered the production efficiency and increased production costs.
(3) To consider the energy consumption of equipment in the premise of meeting the process requirements, try to reduce the installed capacity, avoid the phenomenon of large horse-drawn car, make full use of inherent resources, reduce unnecessary energy waste, achieve the full load of equipment utilization and maximize energy utilization, increase corporate efficiency and social benefits.
5.2 The development of a correct and reasonable production process is the key to reducing the cost of resin sand casting production process is developed reasonably or not, directly affects the yield of the casting, casting quality and casting costs, in the development of the production process, the main should determine the following.
(1) determine the appropriate LOI value of the recycled sand
LOI value, that is, burn reduction is an important indicator to measure the rate of regenerated sand decontamination, but also with the amount of sand gassing and castings produce porosity class defects closely related to the indicators, cast iron parts are generally produced using furan resin sand, practice has proved that LOI value control at about 3% can fully meet production requirements, while some enterprises require LOI value control at 2.5% or less, to achieve this purpose, it is necessary to increase the Equipment, or increase the number of sand regeneration, or add more new sand, which will undoubtedly increase the investment in equipment and regeneration costs and raw material costs. Our company in the production process, gradually relax the LOI value control index from about 3% to about 4%, due to the process and proper management, and did not affect the quality index of the castings because of the change of LOI value.
(2) Determine the appropriate casting process parameters
Determine the appropriate final strength generally, resin sand mixed, after about 24 hours of self-hardening, it can reach the highest strength that is the final strength. Due to the different production conditions and production scale of each enterprise, the time interval between molding and pouring is not necessarily more than 24 hours, so the final strength should be determined by the enterprise. Smaller scale, the implementation of a few days a furnace system of enterprises, can be used 24 hours final strength standards; casting curing time does not exceed the 24 hours of enterprises, the strength reached before pouring as the final strength standards. At the same time, in production to overcome the tendency of two aspects: on the one hand, to ensure the quality and blindly improve the strength, so that the casting cost increases, resulting in waste; on the other hand is to protect the cost and depress the strength, resulting in unstable quality, fluctuations in the range, so that the quality of castings by raw materials and the operator''s influence is greater. Each enterprise should determine the appropriate final strength according to their own situation, so as to achieve maximum savings in resin and curing agent under the premise of ensuring the quality of the casting, reduce casting costs.
(3) Determine the appropriate sand-iron ratio of self-hardening resin sand because of its high strength, curing after starting the mold, the parting surface is flat, so its sand eating amount is smaller than that of clay sand, but its sand-iron ratio also has certain requirements. If the casting sand-iron ratio is too high, the production process will waste resin and curing agent and produce a large block of waste sand, which will increase the burden on the regenerator, reduce the release rate, increase the LOI value, and increase the possibility of pores in the casting; if the sand-iron ratio is too low, it is easy to produce a runner when pouring, and the casting is easy to produce deformation. According to our experience, the sand-iron ratio should be selected as 2.2~3:1.
(4) determine the appropriate modeling process casting yield rate, directly affects the casting cost, the appropriate modeling process can not only ensure the quality of castings, but also reduce casting costs, reduce the casting scrap rate is one of the most obvious and direct measures to reduce casting costs. In determining the molding process, try to make special sand box, box wall more air holes, the model to do the actual sample, using the template modeling, pouring system using ceramic tubes, internal sprue to take more and disperse, paint coating evenly, do not leak coating, set up more air bubble, to ensure that the core exhaust smoothly.
5.3 The correct choice of raw materials is the basis for reducing the cost of resin sand casting. The choice of raw materials has a greater impact on the casting cost, which has been recognized by the vast majority of peers, because the raw materials are good or bad, on the one hand, affects the amount of various materials added and consumed, on the other hand, affects the quality of the casting index.
(1) the choice of raw sand
The original sand is divided into ordinary sand, washed sand, scrub sand and other types, due to scrubbing sand in the mud content has been very little, so it can greatly reduce the waste of resin, should be preferred, followed by washed sand, but never use the original sand without treatment. The price of scrubbing sand itself is not high, generally 50 yuan / t to 70 yuan / t, but its freight is high, such as our company to buy a sand factory in Dalin scrubbing sand for 65 yuan / t, but transported to the company, the total cost of 280 yuan / t. When choosing the type of sand, one should follow the principle of choosing the nearest, so that on the one hand can reduce the expensive freight, on the other hand, to protect the supply, does not affect production. Secondly, we should try to use the raw sand with low angular coefficient. At the same time, due to the scrub sand production enterprises of the technical level and equipment equipment level is different, the quality of its production of scrub sand is also different, therefore, if there are conditions, in determining the use of sand, scrub sand production enterprises should be inspected to examine its technical condition, equipment condition and sand source condition, etc., and find each other from the sand quality control results. In short, in the process of selecting the original sand, it is best to make reference to other aspects of the problem by means of experimental comparison, to ensure production and quality under the premise that the production cost is reduced to a minimum.
(2) The choice of resin
The price of resin is expensive, generally in the 10000 yuan / t or so, so it has a greater impact on the cost of casting, while the quality of the resin produced varies greatly due to the uneven production equipment of manufacturers. If you choose a poor quality resin, not only affect the quality of the sand, resulting in increased casting scrap, but also increase the amount of resin added, the direct result is to increase the cost of casting, so the choice of raw materials, not only according to the technical data provided by the manufacturer to determine, but should be the manufacturer''s production equipment, production process and quality control means to understand, and try to carry out their own indicators of the resin We should try our best to inspect the indicators of the resin or ask the relevant inspection department with good reputation to carry out the inspection, or draw on the experience of similar manufacturers, or choose the products of well-known large enterprises with good reputation. Our company has been using the resin produced by Jinan Shengquan Group since the beginning of production. Because of its better quality and stable performance, although its price is higher than that of some enterprises, its actual production cost is not high due to its lesser amount of addition and stable production process.
(3) The choice of other raw materials
Other raw materials, including curing agent, paint, binder, release agent, sealing clay bar, etc., these raw materials on the quality of the casting is not the main impact, but the impact on the cost of casting can not be ignored, such as the amount of curing agent added to the different, not only due to the impact of molding process productivity and affect the production cost, but also affect the cost of materials. Therefore, the choice of other raw materials principle is to consider both its quality, but also to consider its match with the main materials such as procurement, transportation and other issues. In short, as long as the equipment selection is reasonable, reliable performance, normal operation, matching raw material selection, stable quality, timely supply, reasonable production process parameters, tooling apparatus to ensure that the self-hardening resin sand casting can control and reduce the casting costs, bringing development and benefits to enterprises.
Qingdao Sanzhuji Equipment Manufacturing Co., Ltd. specializes in the production of Green Sand Molding Line,Self-hardening sand molding line,foundry machines,Sand molding machine,Sand casting equipment,sand mixer,GS high efficiency rotary mixer,Resin sand mixer,no-bake resin sand mixer,Jolt squeeze molding machine/Jolt-squeezing moulding machines,Multi- Piston Moulding Machine/Hydraulic multi-piston moulding machine,sand casting molding machine,sand reclamation equipment，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.
