Influencing factors of resource demand in dieless sand casting

Sand casting is a complex and complete manufacturing system. Almost every casting process has the input and output of resources and energy. By analyzing the influencing factors of resource demand of Moldless sand casting, the influence mechanism between casting process scheme setting and resource demand can be determined, so as to effectively control the environmental impact caused by casting cost and reduce material waste in the early stage of process implementation. Combined with the process characteristics of Moldless sand casting and the corresponding resource demand attribute relationship of each process, the influencing factors of resource demand of Moldless sand casting are analyzed from four parts: mold forming method, mold inherent attribute, mold casting coupling and casting batch production conditions.

Specifically, different mold forming methods will produce different resource consumption results, such as molding sand materials, dosage, power consumption of casting auxiliary equipment, personnel arrangement of casting process, etc; The inherent properties of mold include molding sand material, resin curing agent ratio, mold heat storage coefficient and molding sand compactness; Mold casting coupling refers to the part related to mold process design and casting process design. The design of mold first needs to consider the requirements of casting structure, including the minimum wall thickness, critical wall thickness, inner wall thickness, transition and connection of casting wall, casting slope and rib, so as to design and adjust the mold size and mold wall thickness. Among them, the minimum wall thickness of the casting is related to the fluidity of the molten metal and the contour dimension of the casting. It shall be ensured that the design of the wall thickness of the casting is not less than the minimum wall thickness; In view of the problems of shrinkage porosity, shrinkage cavity and coarse grain in the casting production of thick wall castings, it is necessary to consider the critical wall thickness of casting alloy to save metal consumption. The determination or change of the structure of the above castings will have an impact on the structure of the mold, resulting in different demands for metal, molding sand, energy and other resources. In addition, the batch production condition of casting is one of the influencing factors of casting resource demand. For example, in the traditional casting process, for mass casting production, technologically advanced molding and core making processes are usually selected, horizontal or vertical parting non box high-pressure molding production lines are applied, or automatic molding production lines such as high-pressure molding and static pressure molding are adopted to improve production efficiency and reduce the consumption of invisible resources in the casting process. The production conditions of different enterprises, including equipment, site, staff quality and production habits, will also lead to different economic benefits and resource needs. For dieless sand casting and composite mold forming, under the condition of casting batch production, the use of batch casting auxiliary equipment can not only effectively shorten the casting hours, but also further reduce the resource consumption due to the old sand regeneration of molding sand materials, the equal sharing of wood patterns and steel shot materials.

Firstly, the characteristics of mold less sand casting process are analyzed. Combined with the casting process flow, the flow direction of material flow, energy flow and waste logistics are explained. Secondly, the mold characteristics in dieless sand casting and the division rules of mold modules based on compound forming method are discussed. Finally, the influencing factors of resource demand of Moldless sand casting are analyzed and classified.