This paper mainly focuses on the low-carbon modeling of Moldless sand casting process and the optimal design of composite mold. It is divided into six parts, and the main contents of each part are as follows:
The first part, combined with the research status of sustainable development of casting industry at home and abroad and the proposal of green casting and other related concepts, analyzes the current research direction and trend of Moldless sand casting and composite casting from the aspects of mold process design, material system, tool wear and milling strategy, This paper points out the foresight of the compound mold of Moldless sand casting and the necessity of low-carbon design, puts forward and discusses the lack of research in energy conservation and emission reduction in this field, especially in the sustainable evaluation method of the process of Moldless sand casting and the optimal design of the compound mold. In addition, it puts forward the research problems of this paper, and analyzes and summarizes the research purpose, significance and main content of this paper.
In the second part, the forming process of Moldless sand casting is analyzed, including the process characteristics, mold characteristics and influencing factors of resource demand. The material flow, energy flow and waste flow direction in the casting process are described, and the division rules of Moldless mold modules based on composite forming are discussed. The influencing factors of resource demand of Moldless sand casting are discussed from four parts: mold forming method, mold inherent properties, mold casting coupling and casting batch production conditions.
In the third part, low-carbon modeling is carried out according to the characteristics of Moldless sand casting process, comprehensively considering the resource consumption, energy consumption and environmental impact of the casting process. Among them, the establishment of resource consumption demand model is based on resource demand factors, which is composed of material resources, energy resources and labor resources. The energy consumption calculation model consists of hot metal smelting energy consumption, casting auxiliary equipment energy consumption and material recovery energy consumption. The carbon emission calculation model consists of material carbon emission, energy carbon emission and unexpected carbon emission. In addition, based on the production efficiency model, the calculation models of energy efficiency ratio and carbon efficiency are established.
In the fourth part, the forming method and material selection of the composite mold are analyzed, and the process parameters of the composite mold are divided into three categories: independent process parameters of the composite mold, correction process parameters of the composite mold and coupling process parameters of the composite mold. The low-carbon optimization design of the coupling process parameters of the composite mold is carried out by using particle swarm optimization algorithm, and the number is divided by mold modules Constrained by mold wall thickness and mold forming time, combined with the low-carbon model in Chapter 3, a composite mold process parameter optimization model with the optimization objectives of reducing resource utilization, energy consumption, carbon emission and processing time is established.
In the fifth part, for a certain type of motor end cover casting, on the basis of given casting process conditions, the process parameter design scheme of single casting method and the original process design scheme of composite mold are put forward. The optimal mold process parameters are obtained by using the particle swarm optimization algorithm in the fourth part. On this basis, the compound mold process optimization design scheme is proposed. The quality of the proposed process design scheme is verified by pouring simulation software. Combined with the actual production results of castings, the low-carbon indexes of single casting technology and composite mold forming are calculated respectively, and the calculation results of three process schemes are comprehensively compared and analyzed.
The sixth part summarizes the research content and prospects the follow-up work.