Facing the situation of sharp competition in the international market after China’s entry into WTO, the casting machine industry should, according to the needs and possibilities of China’s national conditions, combine industry, University and research, explore and innovate, and make great efforts to develop advanced, scientific, efficient, low consumption, practical and advanced technologies with independent intellectual property rights.
For quite some time in the future, wet sand molding will still be the leading molding process because of its mature process, strong adaptability and low cost in mass production. Nowadays, one of the development trends of wet sand molding machine is to increase the mold size to adapt to the on-line molding of large-size castings. Accordingly, a super large and efficient sand mixer with a capacity of more than 10 OT / h is designed and manufactured.
Resin sand molding will continue to be developed because of its high precision, simple operation and fast starting, especially for medium and large parts. In addition, because of its high mold strength, resin sand non sand box modeling will be popularized. Over the years, the traditional drying sand mold process in China will soon disappear in the casting industry.
In terms of core making, due to environmental protection, the cold core box process will dominate in the future
。 However, sometimes for process considerations, it is desirable to have a hollow core, so the shell core will also be developed to a certain extent.
2.Cast alloy material
Develop new cast iron materials with the goal of strengthening and toughening, lightweight, precision and high efficiency; Focus on the development of Austempered Ductile Iron (ADI) heat treatment equipment, formulate national standards as soon as possible, and promote new technologies of Austempered Ductile Iron (such as interrupted hot sand dropping method, interrupted normalizing method, etc.); Develop manufacturing technology of thin-walled high-strength gray iron castings, manufacturing technology of Cast Iron Composites (such as in-situ reinforced granular iron matrix composites), surface or local strengthening technology of cast iron castings (such as surface laser strengthening technology).
Develop new special alloy materials with wear resistance, corrosion resistance and heat resistance; Develop new varieties of cast alloy steel (such as nitrogen-containing stainless steel and other cast steel materials with high performance price ratio), improve material properties, utilization rate, reduce cost and shorten production cycle. Develop high-quality aluminum alloy materials, especially aluminum matrix composites. Develop new casting composites, such as metal matrix composites, base metal matrix materials and reinforced component materials; Develop technologies to reduce production costs, reuse materials and reduce environmental pollution; Expand the application field of casting Qin alloy and reduce the casting cost.
3.Casting raw and auxiliary materials
Establish a new raw and auxiliary material system suitable for high-density clay molding sand, develop different varieties of raw sand and high-quality shell core sand with less pollution according to the characteristics of different alloys and castings and production environment, pay close attention to the investigation and development of raw sand resources in China, carry out the research to replace special sand and develop artificial casting sand; The development of green sand binder is focused on the development of new pulverized coal and additives to replace pulverized coal. Strengthen the research on the hygroscopicity and collapsibility of sodium silicate sand, especially vigorously develop the new technology of old sand reuse, and recycle the old casting sand as much as possible, so as to reduce the production cost, reduce pollution and save resources.
On the premise of improving the quality of cast pig iron and adopting desulfurization technology, improve the spheroidizing agent formula, reduce the content of magnesium and rare earth and improve the spheroidizing effect: develop spheroidizing agents for special alloys and special processes. Develop refining agent and refining modification bulk aluminum alloy flux suitable for rid and FL technology.
Develop large-scale cupola of more than 5 t / h, and adopt external hot air supply, water-cooling and unlined continuous operation cupola as required; Promote the double smelting process of cupola induction furnace; Advanced liquid iron desulfurization and filtration technology are widely used, equipped with direct reading spectrometer, rapid carbon equivalent tester, quantitative metallographic analyzer and spheroidization rate detector, and microcomputer technology is applied to thermal analysis of cast iron melt. Promote the dehumidification and air supply technology of cupola, utilize the waste gas of cupola, eliminate environmental pollution and improve the quality of molten iron. Induction furnace has the advantages of flexibility, energy saving and high efficiency. The use of induction furnace is the development direction of cast iron smelting technology in the future. However, as the main smelting furnace, the status of cupola is still expected to remain for a long time in China.
In the production of aluminum alloy castings, the refining technology, modification technology, grain refinement technology and rapid detection technology in front of furnace, which are pollution-free, efficient and easy to operate, are emphatically solved. For alloys of different brands and uses, the optimization of solid solution and aging treatment process parameters is studied by computer numerical simulation technology, so as to give full play to the material potential and improve the material properties. Introduce and digest advanced refining technologies such as rid and FL to improve the melting level of aluminum alloy.
Further study the magnesium alloy melting process, strengthen the serialization and commercialization of pollution-free and efficient flux for magnesium alloy melting and the development of gas protection technology, strengthen the development of casting, recovery and remelting technology of high-purity cast magnesium alloy materials, magnesium rare earth heat-resistant cast magnesium alloy materials and magnesium matrix composites, and further strengthen magnesiumThe research and development of squeeze casting technology to meet the needs of the development of China’s automobile industry. Improve the Qin alloy melting equipment, solve the existing problems of mold materials, carry out research on the influence of mold heating mode and mold preheating temperature on casting quality under vacuum, research on the volatilization behavior of alloy elements and its influence on alloy composition under vacuum melting, research on the influence of impurity elements on Qin casting quality, research on the optimization of melting and parameters of different alloys under different conditions Research on investment casting materials and process of Qin alloy, hot isostatic pressing and welding repair process of castings.
Develop precision forming technology and near precision forming technology, vigorously develop visual casting technology, and promote the five-way integrated, virtual, intelligent and practical development of casting process numerical simulation technology CA; Foundry CAD system based on characteristic modeling will be the basis and premise for foundry enterprises to realize modern production process design. The new generation foundry CAD system should be an integrated system integrating simulation analysis, expert system and artificial intelligence.
Adopt modular system and unified data structure, and seamlessly integrate with cam / CAPP / ERP / rpm, etc; Promote the further improvement of the modernization level of casting tooling, comprehensively carry out the integration, intelligence and online operation of CAD / CAM / CAE / RPM, reverse engineering, concurrent engineering, remote design and manufacturing, computer detection and control system, and urge the revolutionary progress of traditional casting industry.
Focus on the research, development and application of integrated casting information processing system that can cover all behaviors of casting enterprises (including enterprise marketing, material in and out, production organization and coordination, administrative management, information exchange with the outside world, etc.), and quickly transform the traditional casting industry with modern advanced technology.