No matter what products or things we are operating, there will be many problems that need to be paid attention to. We need to understand clearly before we can carry out it. The same is true for precision casting. What are the six problems that should be paid attention to in the process of precision casting?
1. Using optimized design and process to improve the process yield of precision castings. On the premise of ensuring the quality of precision castings, changing the gating system and using heating and insulation risers can usually improve the export rate. If the export rate can be increased from 60% to 70%, the energy consumption can be reduced by 14.3%.
2. The molding machine with high compactness and modern core making technology are adopted to reduce the casting quality and machining allowance as much as possible. Practice has proved that high pressure molding can reduce the casting quality by 3% – 5% compared with manual molding and ordinary machine molding, and the machining allowance can be maintained at 2-3mm. Reducing weight can not only save energy in and precision casting workshop, but also reduce the energy consumption of subsequent processing.
3. Precision castings adopt energy-saving process flow and reasonably organize production. For example, use self hardening resin sand or surface dry mold instead of clay sand drying mold to save energy consumption for drying mold; Strictly proportioning, determining the appropriate composition of precision castings, adopting effective inoculation scheme, eliminating white spots or hard spots on castings as cast, so as to cancel the graphitization annealing process; Popularizing as cast ductile iron requires that all ductile iron with elongation below 12% after fracture should be obtained in as cast state; The frequency wave harmonic vibration aging process shall be adopted as far as possible, and the stress relief thermal aging process shall be removed.
4. Save materials and try to reuse them. Because the production of any material requires energy consumption.
5. Large scale production of precision casting steel enterprises, that is, the output of each casting unit is more than 5000t. Because of the large output of the enterprise, the working time of the furnace is long, and the energy consumption of heating energy of the furnace itself can be greatly reduced by sharing it with each ton of precision castings.
6. Improve the management level and reduce the scrap rate. For example, for a precision foundry with an annual output of 5000t, every 1% decrease in the scrap rate is equivalent to producing 50t more precision castings. Based on the energy consumption of 400kgee per ton, 20t standard coal can be saved a year, that is, the energy consumption of 4kgee per ton of precision castings can be reduced.
Hebei Junya Precision Machinery Co., Ltd., founded in 2017, is a high-tech enterprise integrating product design, mold development, casting, processing, surface treatment, testing and inspection and sales services. The factory covers an area of 5000 square meters and is located in Huanghua economic and Technological Development Zone, Hebei Province. The company has superior geographical location and convenient transportation. After years of development, the company has introduced advanced production equipment and management experience in various industries, and trained dozens of excellent professional R & D and technical talents.
At present, the company has more than 100 employees and more than 20 technical and R & D personnel. The company’s main products are stainless steel cast pipe fittings, quick connectors, ball valves, check valves, precision accessories, marine hardware, cast auto parts, etc. The product material is mainly 304 304l316 316lcf8m WCB 1.4408, etc. The company officially passed ISO9000 certification in 2020 and is actively preparing for TS16949 quality system certification. With its good product quality and reputation, the company has become more and more prominent in the international market, with partners all over the world.
In 2019, the export volume accounted for more than 60% of the total sales, and has established long-term and stable cooperative relations with many enterprises in Europe, the United States and Japan. The company always adheres to the business philosophy of heart, innovation and ingenuity. Based on the principle of seeking development from R & D, meeting opportunities in development, building trust in opportunities and consolidating contacts in trust, we look forward to cooperating with you. For details, please contact 18902146189.
3、精密铸件采用节能的工艺流程，合理组织生产。如：使用自硬树脂砂或表面干型替代黏土砂烘干型，节约烘干铸型的能耗；严格配料、确定精密铸件的合适成分、采取有效的孕育方案，在铸态就消除铸件上的白口或硬点以取消石墨化退火工艺；推广铸态球铁，要求断后伸长率在12%以下的都应在铸态下获得；尽量采用频波谐波振动时效工艺，去掉减应力热时效工艺。
4、节约材料，努力回用。因为任何材料的生产都需要耗能。
5、精铸钢企业规模化生产，也即每个铸造单元的产量在5000t以上。因为企业产量大，熔炉的工作时间就长，炉子本身的加热耗能平摊到每吨精密铸件上的能耗就可大为减少。
6、提高管理水平，降低废品率。如，一个年产5000t的精密铸造厂，废品率每下降1%，就等于多生产50t精密铸件，按每吨能耗400kgee计算，一年能节约20t标煤，也即每吨精密铸件降低了4kgee的能耗。
Post time: Apr-29-2022
