Concept And Design Basis Of Casting Process Design

1. concept
The development of modern science and technology requires metal castings to have high mechanical properties, dimensional accuracy and low surface roughness value; some special properties, such as heat resistance, corrosion resistance, wear resistance, and short production period and low cost. Therefore, before the production of casting, the casting process should be designed, so that the whole process of casting can achieve scientific operation, in order to effectively control the formation process of casting, to achieve the effect of high quality and high yield.
Casting process design is the process of determining the casting scheme and process parameters, drawing the casting process map and compiling technical documents according to the structural characteristics, technical requirements, production batch and production conditions of casting parts. Relevant documents of casting process design are the basis for production preparation, management and casting acceptance, and are used to direct production operations. Therefore, the quality of casting process design plays an important role in the quality, productivity and cost of casting.
2. design basis
Before the casting process design, the designer should master the production tasks and requirements, and be familiar with the production conditions of the factory and workshop, which are the basic basis of the casting process design. In addition, the designer is required to have a certain production experience and design experience, and should have an understanding of the advanced casting technology. Having economic and development views can complete the design task well.
(1) Production tasks
(1) The drawings provided by the casting parts drawings must be clear and correct, with complete sizes and various marks. The designer should carefully review the drawings. Pay attention to whether the structure of the parts conforms to the casting process. If it is considered necessary to modify the drawing, it shall be studied jointly with the original design unit or the ordering unit, and the modified drawing shall be taken as the design basis after obtaining a consensus.
(2) Technical requirements of the parts: metal material grade, metallographic organization, mechanical properties requirements, casting size and weight tolerance and other special performance requirements, such as whether the water pressure, air pressure test, the working conditions of the parts on the machine, etc. Care should be taken to meet these requirements in the casting process design.
(3) Quantity of products and production period The quantity of products refers to the batch size. Production term is the length of the delivery date. For large batch products, advanced technology should be adopted as far as possible. For emergency single products, it should be considered to make the process equipment as simple as possible, so as to shorten the production cycle and obtain greater economic benefits.
(2) Production conditions
(1) Equipment capacity includes the tonnage and maximum lifting height of lifting conveyor, form, tonnage and productivity of furnace, shape and type of core maker, mechanization degree, capacity of drying furnace and heat treatment furnace, pit size, plant height and gate size, etc.
(2) Application and supply of raw materials in the workshop.
(3) Technical level and production experience of the workers.
(4) Processing capacity and production experience of the mold and other process equipment manufacturing workshop.
(3) Consider the economy
The price of all kinds of raw materials, furnace, the cost of each ton of liquid metal, the cost of all levels of work, the hour cost of equipment should be understood, so as to assess the economy of the process.