In view of the serious casting defects in the small batch production process of ZHY Casting motor shell steel castings, resulting in high scrap rate and production cost, unable to ensure product quality and on-time delivery, a process optimization scheme to solve the casting defects of motor shell is put forward from the perspective of casting technology. The main research contents are as follows:
① This paper introduces and analyzes ZHY Casting motor shell products and existing production technology.
② The cracks and sand inclusion defects occurred in the actual production process of ZHY Casting are classified and analyzed to determine their causes.
③ According to the analysis results, combining theory with practice, the manufacturing process is optimized and tested to determine the feasible process method.
④ Through the statistical analysis of engineering practical application data, the results obtained after the implementation of process optimization are displayed, which provides reference and basis for further improving the manufacturing process of motor shell and solving the sand casting defects of motor shell in the future.
The structure is as follows:
1) The research background and significance of this paper are put forward, and the application of different molding sand processes in steel castings (motor shell) is introduced combined with references; The development of sand casting process and smelting pouring process of motor shell are introduced.
2) Current situation of production process of motor shell in GC company. Analyze and introduce the requirements of product material, structure and quality. The molding sand process, casting process and smelting casting process are briefly introduced, and the product quality problems caused by this process are statistically analyzed. It is concluded that sand inclusion and crack are the main defects.
3) Defect analysis of motor shell. The causes of hot cracks include the structure and material of sand casting of motor shell, furan resin sand process and sand casting process design. The main causes of sand inclusion are unreasonable design of gating system, damage of sand mold and low strength of local molding sand.
4) Research on process optimization of motor housing. Optimization and test of molding sand process, optimization design of fillet with more cracks in sand casting structure, optimization of sand casting process scheme, optimization and control of chemical composition of molten steel, design of casting temperature, etc.
5) Production practice and effect. The case and data of practical engineering application show that the optimized process scheme is reasonable and scientific.
Understand the application and development of steel casting motor shell in clay sand process, sodium silicate sand process, furan resin sand process and alkaline phenolic resin sand process; The development of sand casting process and smelting pouring process of motor shell are introduced. The main contents of casting defect analysis and process optimization of motor shell steel castings are described.