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The development and continuous improvement of the lost foam casting method is the evolution process from the foam model wet sand method (FM method) to the foam model thousand sand negative pressure method (FV method). This kind of evolution is not only the evolution of the modeling method, but the fundamental change of the process principle. The disappearance of the bubble model has undergone a fundamental shift.

The solid-cast foam model is violently burned away under open conditions.

Dry sand solid casting is mostly used for cast aluminum body, and the foam model disappears mainly in liquefaction mode.

The negative compaction type dry sand (foam mode) casting method, the foam model disappears in a gasification-based manner.

The three methods described above not only have different ways of disappearing the foam, but also the principles of the setting are different. Therefore, the requirements for the performance of the coatings are not the same.

The solid casting relies on the powdering agent to shape the sand and the open casting. The coating mainly acts as a partition between the molding sand and the liquid metal to prevent the sand from being difficult to remove.

The setting mechanism of the dry sand solid casting sand without vacuuming is relatively complicated. This method must be filled by the bottom of the model to the human metal liquid, and the liquid metal is filled by the static pressure, and the radiation heat conduction mode is adopted during the rising process of the liquid surface. The carried heat is transferred to the foam model, and the foam shrinks rapidly after being heated, liquefying and dripping on the surface of the liquid metal layer. The liquid foam dropped on the surface of the liquid metal is subjected to a higher temperature and rapidly vaporized to generate a high pressure gas. The sand in the air gap is the shape of the model cavity that is maintained by the high pressure of the gas.

The continuous convex form of the molten metal surface rises, and the liquid foam is instantly squeezed between the liquid metal and the coating. In order to avoid the occurrence of casting defects, this method requires the coating to have good wetting properties, absorb the liquefied material of the foam model, and remove the liquefied material of the foam model into the sand gap under the action of the liquid metal pressure.

Under the action of high temperature of liquid metal, the liquid foam continuously vaporizes into the peripheral sand gap during the discharge process. At this time, the vaporized foam is condensed into a liquid substance in the cold, so that the molding sand is bonded and shaped.

In the state of vacuuming, the pressure difference generated by the atmosphere makes the sand compact as hard as a stone. This paper discusses the problems related to the coating used in the lost foam casting method with foam model, dry sand and vacuum. .

There are three methods of using foam casting. Although the foam molds disappear, in China’s atmosphere, only the casting method with three types of foam, dry sand and vacuum should be called lost foam casting.

Lost foam casting currently has three processes

Since the entry into China in the early 1980s, lost foam casting has experienced a long period of chaos. It has been circulating in the industry – the words: seemingly simple lost foam casting, a look If you do it, it will be scrapped!

As an independent technical method, lost foam casting should have its own theoretical basis. It is precisely because we neglect the study of the unique theory of lost foam casting. For a long time, we borrowed the theory of traditional casting to explain the lost foam casting. We have entered a misunderstanding with the actual ambiguity.

When we asked ourselves what topics should be studied for lost foam casting, we discovered that the name of the lost mold is very appropriate! Very good! Three words set the theme!

Lost foam casting is to study: the mold disappears!

To put it simply, we need to study three problems in the disappearance of the mode: the way the mode disappears, the time the die disappears, and the amount of die disappearance.

(1) The disappearance mode of the lost foam casting mold

The lost foam casting mold is a compound mainly composed of carbon and hydrogen, and it disappears in two ways.

Gasification disappears;

The burning disappeared.

In the process of casting in the lost foam casting, if the liquid metal can close the sprue and not let the air enter the cavity, the foam of the model will be cracked into small molecules by the macromolecule under the condition of high temperature and no oxygen, and the solid state will change into the gaseous state. The coating is vacuumed and discharged.

If air is drawn into the cavity during the casting process, the foam will burn violently. This common sense is shared by everyone. Foam burning produces a lot of free carbon and carbon bundles. This is because the concentration of oxygen in the air is insufficient, and the active hydrogen atoms combine with oxygen to free the carbon. When free carbon and carbon bundles are dissolved in liquid metal, diffuse carbonization occurs, and carbon segregates bright carbon, which changes the material quality, quality and processing properties of the casting.

The carbon concentration of gray iron and ductile iron is higher, the carbon adsorption tendency is not obvious, the carbon concentration of carbon steel is very low, the greedy absorption of carbon, the free carbon produced by foam combustion becomes a deadly killer of steel castings. Therefore, in the early days, few people were able to make casting molds for lost molds, especially small dry cast steel parts.

We know the principle of free carbon generation. We also know the danger of free carbon. We also know that the occurrence of free carbon is inevitable. As long as there is a way to make the free carbon produced by combustion out of the cavity, it is insoluble in liquid metal. It can prevent the occurrence of carbonization defects. Therefore, we tried to cast directly from the riser. The spacious riser channel allows the gas and free carbon produced by the combustion of the foam to be fully discharged, solving the serious carbonation problem of the casting. The open casting method is to solve the problem of carbon-discharging. Therefore, we call it the carbon-discharging method of lost-foam casting, which is mostly used for thick and cast steel parts that require Zengkou feeding. The closed casting method corresponding to this is to create a condition of high temperature and no oxygen, and to make the foam gasification disappear, so we call it the gasification method of lost foam casting.

(2) The disappearance time of the lost foam casting mold

a. The disappearance of the lost foam casting mold is actually the replacement of the liquid metal with the foam type. Since it is a replacement of two substances, there are three manifestations in the time relationship between one in and one out;

b. The filling speed of the liquid metal is faster than the disappearing speed of the foam model;

c. The filling speed of the liquid metal is synchronized with the disappearing speed of the foam model. If the filling speed of the liquid metal is faster than the disappearance of the foam model, the liquid metal will be buried in the foam before the foam cutting bottom disappears and fills the cavity. The gel, which causes the gas to continue to vaporize, cannot escape from the cavity and solidify in the casting, creating pore defects, which we do not want to happen. We hope that the rate of disappearance of the foam (whether gasification or combustion) will disappear with the filling of the liquid metal or before the filling of the cavity with the liquid metal. Thus, the disappearance of the foam type has no effect on the filling of the liquid metal. Therefore, when we summarize the design principles of the lost foam casting system, we propose to control the cross-sectional area of ​​the sprue, balance the feed rate of the liquid metal and the gasification speed of the foam. The best way is to burn the foam model first or first.

(3) Loss of lost foam casting mold

In the lost foam casting process, we hope that the foam will disappear completely without leaving any traces. The special defects such as pore defects, carbonization defects, and wrinkle defects in lost foam casting are traces of the mold lost during the disappearance process. We are known as: gasification defects.

The measures to overcome the gasification defects are – in general terms, seven words: one low, two high, three breathable. Namely: use a lower density foam model, higher temperature molten iron and a coating with good permeability.

In this article we outline three process and theoretical foundations for the development of lost foam casting to date. The three methods are:

(1) “sealed pouring” of lost foam casting gasification method;

(2) Lost-die casting carbon discharge method “open pouring”;

(3) The lost shell casting method of empty shells is “first burned and then poured”.

The purpose of introducing the three methods is to show that the development of lost foam casting has not been a single method, and the requirements for coating performance are different.

With the continuous development of the foundry industry, the most popular casting process used by Chinese foundry manufacturers in 2017 is lost foam and sand casting. Generally, manufacturers of single large-volume precision castings generally adopt the lost foam casting method, which mainly undertakes outsourcing and zero-lived foundry manufacturers. Most lost foam and sand casting are in use. Let’s summarize the advantages of the lost foam and sand casting.

According to the comparison between sand casting and lost foam production process, the lost foam has eight advantages over sand casting: wide production range and high precision standard. Suitable casting castings can reduce running cost, short cleaning time, suitable for mechanized production, and workers can find Easy to organize production quickly, high pouring efficiency and high customer satisfaction!

Since the molding materials used for sand casting are cheap and easy to obtain, the castings are easy to manufacture, and can be adapted to single-piece production, batch production and mass production of castings. For a long time, it has been the basic process in casting production. Sand casting is used to produce “a variety of complex geometric shapes of metal parts. These parts can vary greatly in size and weight, from a few grams to a few tons. Some smaller sand castings include component gears, pulleys, crankshafts, Connecting rods. Larger applications include large equipment and heavy machinery base housings. Sand casting is also suitable for the production of automotive components such as engine blocks, engine cylinder heads, and gearboxes.

The lost foam casting is a model made of foam material. After painting the special coating, it is buried in the negative pressure sand box with dry sand. After the dry sand is compacted by vibration, the metal liquid is poured under negative pressure. Thus, a casting having no flash burr consistent with the foam model is obtained. The foam model vaporization disappeared during the casting process, so the image was called lost foam casting.

Lost Foam Casting (also known as solid casting) is a combination of a paraffin or foam model similar in shape to the shape of the casting into a model cluster. After brushing the refractory coating and drying it, it is buried in the dry quartz sand for vibration molding, under negative pressure. Under the pouring, the model is vaporized, the liquid metal occupies the position of the model, and a new casting method for forming a casting after solidification and cooling is formed.

The eight main advantages of lost foam and sand casting are detailed:

1, Wide production range

Lost foam casting does not require parting and lower cores, so it is especially suitable for box-type, shell-like castings, and bobbin-type castings with complex geometric shapes and difficult traditional casting.

2, high precision standard

High dimensional accuracy can be achieved and thin walls (ie 3mm) can be cast. Because of the lack of modeling, the lost foam casting directly adopts the “fusion” method, so the shape of the casting is consistent with the mold. It is not necessary to consider the factors in the sand casting shape, the casting I casting wrong box, the collapse of the box and other artificial castings.

3, suitable castings can reduce operating costs

Compared to conventional sand forming methods, complex castings, especially those requiring high dimensional accuracy and having a thin cross section, can be produced at very high cost.

4, short cleaning time

Lost foam casting has a high dimensional accuracy, and there are no parting lines or vent needles and cores, so burrs and machining can be minimized. Cleaning hours can be reduced by more than 80%.

5, suitable for mechanized production

Lost foam casting is not only suitable for large-volume castings, mechanized operation, but also for manual splicing models of small batches of products.

6, people are looking for easy to organize production quickly

Lost foam casting eliminates the molding process and eliminates the need for skilled stylists. After a short training period, you can become a skilled worker.

7, high pouring efficiency

Lost foam casting is suitable for group casting, and dry sand is easy to remove sand. In some materials, castings can also be used for residual heat treatment according to the application. Multiple castings can be combined in one mold to increase casting efficiency.

8, high customer satisfaction

Lost foam casting is not only suitable for small and medium-sized parts, but also suitable for large-scale castings, such as: machine bed, large-diameter pipe fittings, large-scale cold-punching modules, large-scale mining equipment parts, etc., because the model production cycle is short, the cost is low, and the production cycle is short. Therefore, it is especially well received.

Of course, in some cases, sand casting is still required for casting production, and specific problems should be analyzed. With the advancement of society, casting production is becoming more and more “scientific”, so as a founder, it is necessary to follow the pace of the times and continuously learn and improve the casting production technology.

The sand molding process plays an important role in the casting production process, which directly affects the quality level, production cost, production efficiency and environmental pollution degree of the casting. The sand casting method can be divided into two categories: physical hardening modeling method and chemical modeling method.

The physical hardening modeling methods mainly include clay sand type, solid casting, V method modeling method, and freezing modeling method. Among them, clay sand type is divided into wet type, dry type and dry type. The solid shape and the V method are a binderless method (dry sand) and are formed by vacuum molding. The frozen molding method uses water as a binder.

The chemical modeling methods mainly include: water glass sand type, resin sand type and the like. They can be divided into three types: heat hardening, self hardening, and air hardening. Water glass is an inorganic binder and resin is an organic binder. When selecting a sand molding process, the following principles should be followed:

1. Should be able to guarantee the quality requirements of castings

At present, the widely used molding processes mainly include clay wet sand technology, CO2 blown hard water glass sand process, organic ester self-hard water glass sand process, and acid self-hardening furan resin sand process. In recent years, the hardening sand molding process of ester hardening phenolic resin has also been promoted and applied to a certain extent. The characteristics of these modeling processes, the impact on the quality of castings and the scope of application are as follows:

(1) Clay wet sand process

The advantages of the clay wet sand process are:

A. The raw materials used are cheap and the sources are abundant.

B. The shape is convenient, the sand type does not need to be dried, the casting production cycle is short, the efficiency is high, and it is easy to realize mass production.

C. The bentonite which has not been dehydrated in the recycled sand can be restored after mixing with water. The old sand has good recyclability and less investment in recycling equipment.

D. After a long-term application, a series of modeling equipment has been developed.

E. The dimensional accuracy of castings produced by general modeling is no less than that of chemical self-hardening sand. The high-precision modeling methods such as injection molding, air-punching and static pressure modeling can produce dimensional accuracy comparable to investment casting.

(2) CO2 blowing hardened water glass sand process

Ordinary CO2 blowing and hardening water glass sand process is the earliest rapid prototyping process in the field of water glass binder. Its main advantages are:

A. The device is simple, easy to operate and flexible to use.

B. the binder is non-toxic and tasteless, and the cost is low.

C. The sand type has high temperature repellent property and the shrinkage stress of the casting is small.

D. The binder system does not contain S, P, N, and there is no sulfur increase on the surface of the casting.

The CO2 blowing hardening water glass sand process has been widely used in the production of most steel castings at home and abroad, and is mainly used for the production of medium and small steel castings. However, the shortcomings of the CO2 blown hardened water glass sand process are also very obvious:

A. The sand type (core) has low strength and the water glass is added in a high amount.

B. large water content, easy to absorb moisture, poor hard penetration in winter.

C. The sand type (core) has poor collapsibility, the old sand is difficult to regenerate, and a large amount of old sand is discarded.

In the past, the problem of collapsibility and reuse of old sand was not well solved, which affected the expansion of water glass sand to a certain extent. In recent years, people have made breakthroughs in deepening the understanding of the basic composition of water glass and the essence of “aging” phenomenon and new hardening processes (such as vacuum-exchanged CO2 gas hardened water glass sand process), which are maintained in core sand. Under the condition of sufficient process strength, the high-quality natural silica sand with low content of mud can reduce the amount of water glass to 4.0%, so that the long-term existence of water-glass sand is poor, and the old sand can not be reused. Good solution. Water glass old sand recycling equipment has also matured, and water glass sand has developed a good momentum.

(3) Organic ester self-hardening water glass sand process

Organic ester self-hard water glass sand is widely used in cast steel and has certain applications in cast iron. The main advantages of this hardening process are:

A. The molding sand has a high strength, and the amount of water glass added can be as low as 2.5-3.5%.

B. Sand type (core) has good collapsibility, and the old sand dry regeneration rate is ≥80%.

C. The sand type has good thermoplasticity and low gas generation, which can overcome the defects such as cracks and pores which are prone to occur when the furan resin sand is used to produce steel castings. The quality and dimensional accuracy of the castings are comparable to those of the resin sand.

D. The production cost is the lowest and the working conditions are good in all self-hardening sand processes.

The hardening process still has the following disadvantages: the core sand hardening speed is slow, the brittleness is large, and the fluidity is poor.

(4) Acid self-hardening furan resin sand process

Acid self-hardening furan resin sand and organic ester self-hardening water glass sand are typical representatives of organic binder chemical self-hardening sand and inorganic binder chemical self-hardening sand. The common features of chemical self-hardening sand process are:

A. After the sand type hardens, the mold sand does not need high wet strength, the sand has good fluidity, the sand type has high strength, the deformation is small, the tooling is simplified, the shape is simple, the sand type does not need to be dried, and the dimensional accuracy of the casting is significantly improved, which can reach CT8~ Level 10, casting defects are also less.

B. Chemically hardened sand generally uses a liquid self-hardening binder. Therefore, it requires high quality of the original sand to minimize the amount of binder added.

C. Since the hardening of the binder is an irreversible chemical reaction, it cannot be re-used as simply as clay sand. When used in large quantities, a relatively complete old sand regeneration system must be used.

D, the model structure and surface quality requirements are higher, in order to demould.

The self-hardening sand process is mainly suitable for small batch or batch production of large-scale castings, and there is no competition or substitution relationship with the clay wet sand technology.

The acid self-hardening furan resin sand process is a self-hardening sand process which is widely used in cast iron, and its outstanding advantage is that the sand type (core) has good collapsibility and the old sand regeneration has high recycling rate.

The furan resin used in the foundry production needs to be modified with urea-formaldehyde and applied to the non-ferrous alloy, gray cast iron, ductile iron and cast steel according to the nitrogen content of the modified resin.

The disadvantages of the acid self-hardening furan resin process are:

A. The N, S, P and other gases generated after the pyrolysis of the resin binder and the curing agent may cause severe osmosis of the surface of the ductile iron casting and the steel casting, causing defects such as pores and cracks.

B. Sand type has high thermal expansion rate, large thermal stress, poor high temperature retreat, large shrinkage stress of castings, and cracks and burrs in castings.

C. The resin binder is expensive, and the furan ring produced after decomposition is very harmful to human health.

(5) ester hardening phenolic resin self-hardening sand

The ester hardening phenolic resin self-hardening sand process was developed by Bolton Company of the United Kingdom and is called a-set process. It was patented in 1981 and has been widely used in Europe in 1984. It was first used in cast steel production and has been expanded to Cast iron and non-ferrous alloy castings.

The phenolic resin has a strong basicity and a pH of from 1 to 13.5. The resin contains organic solvent, low flash point, flammable, and soluble in water. The shelf life is short. It can be stored for 6 months at 20 °C, 2-3 months at 30 °C, and only 1- at 40 °C. 2 months.

The hardener of such self-hardening sand is an organic ester, which can be selected according to the requirements of the curing speed. The amount of hardener is about 20~30% (mass fraction) of the resin, and the amount of phenolic resin added is 1.5~2.5% of the original sand. The sand mixing process is the same as the acid self-hardening furan resin. The sand temperature is usually controlled at 20~30%, the type (core) sand can be used for 5~30min, and the demolding time is 15~60min.

The main features of ester hardening phenolic resin self-hardening sand are:

A. Only partial reaction occurs under the action of hardener. The mold or core has a certain thermoplasticity after hardening. After pouring the metal, there is a short process of complete hardening due to heat. This is also the difference from the acid self-hardening furan resin sand. Therefore, the mold (core) made by this process is not very strong after hardening, and the compressive strength is only 2 to 4 MPa, but the dimensional stability and thermal stability of the mold are further hardened due to the initial stage of casting. All are good, the castings produced have high dimensional accuracy and good surface quality.

B. Because it does not contain N, P, S, it is especially suitable for the production of steel castings and ductile iron castings.

C, there will be no burr defects. Other self-hardening resin molds exhibit cracks at the mold/metal interface during casting and solidification. While the ester-hardened phenolic resin self-hardening sand has a short-term thermoplastic stage in the surface layer during the casting and solidification process to avoid cracking, a smooth casting with no burr defects can be obtained.

D. Alkaline phenolic resin has wide adaptability to raw sand, and is not only suitable for silica sand, but also suitable for special sand such as magnesia, forsterite sand and chromite ore with high acid value.

2. Should be compatible with the production batch

In mass production, priority should be given to mechanized, automated clay wet sand molding production lines and resin sand core production lines. For small castings of clay wet sand casting, it is possible to adopt a boxless high-pressure molding production line with horizontal splitting or vertical splitting. The production efficiency is high and the floor space is small. For medium parts (greater than 10kg), various high-pressure boxes are available. Modeling production line, pneumatic molding line to meet the requirements of fast, high-precision modeling production line. The old-fashioned shock-type or shock-pressure molding machine has low production line productivity, high labor intensity, high noise, and is not suitable for mass production. It should be phased out.

In medium-volume production, it is possible to consider the application of resin self-hardening sand, CO2 blowing hardened water glass sand, vacuum displacement blown hardened water glass sand molding and core making.

Manual styling is still an important method when producing single-piece small batches. Manual modeling can adapt to a variety of complex requirements, more flexible, does not require a lot of process equipment, can be applied to resin self-hardening sand type, CO2 blowing hardened water glass sand type, vacuum replacement blowing hardened water glass sand type, organic ester water glass self-hardening sand type , clay dry type and cement sand type. For heavy-duty castings produced in one piece, the pit-forming method is low in cost and quick in production.

The multi-box shape and the box-boxing method are suitable for mass production or long-term production of styling products. Although the initial investment of molds and sand boxes is high, it can be compensated for from saving man-hours and improving product quality.

3. Should adapt to the company’s own conditions

The production conditions (including equipment, site, staff quality, etc.), production habits, and accumulated experience of different enterprises are different. It is necessary to consider what modeling method is suitable according to these conditions. The best is applicable. At present, various technologies are competing for development. Each technology has its own advantages, and it also has certain limitations and scope of application. Advanced, high-tech processes are not necessarily applicable. According to the company’s own conditions, it is necessary to make practical choices by selecting technically applicable and economically reasonable processes and focusing on the combination of technology and economy.

For example, when producing castings such as large machine bed, the core forming method can be used, and the mold and the sand box are not made, and the core is assembled in the pit; while the other factory adopts the sand box modeling method to make the appearance.

4. To balance the quality and cost of castings

The quality of the castings obtained by various casting processes is different, the initial investment and production efficiency are also inconsistent, and the final economic benefits are also different. Therefore, to be more, faster, better, and more economical, we should take into account all aspects. Cost estimates should be made for the chosen casting method to ensure both economic efficiency and casting quality.

5. Pay attention to the environmental protection characteristics of the modeling process

Foundry production has always been known for its serious environmental pollution. Its pollution form is mainly caused by air pollution and waste slag pollution caused by steel melting and modeling materials. Among them, air pollution and waste residue pollution caused by modeling materials are the most serious.

According to statistics, it takes about 1t of new sand to produce 1t castings, and about 1t of old sand is discarded. At present, China produces about 28 million tons of castings a year, and the annual amount of old sand discharged is about 28 million tons. This not only accounts for a large amount of natural resources, but also causes serious environmental pollution. In order to reduce the amount of old sand emissions, it is necessary to use the casting process with high old sand recycling rate, clay wet sand and resin sand.

However, the clay wet sand has large dust pollution and black pollution of coal powder. The harmful gas generated by the combustion and decomposition of coal powder during the pouring process also causes serious air pollution; while the air in the resin sand production site is free of many organic substances. Exhaust gas (SO2, formaldehyde, benzene, methyl, etc.) will produce a lot of harmful gases after pouring, which is very harmful to human health. The water glass sand is composed of silica sand, inorganic water glass binder, etc., and uses CO2 gas or organic ester (such as ethylene glycol diacetate) as a curing agent, and the production environment is friendly, and no harmful gas is generated. Compared with clay sand and resin sand, the water glass sand process is the most suitable core making process for green clean casting production.

6. In conclusion

There are many kinds of products to be cast, and the process of modeling is also ever-changing. We must have a scientific attitude when choosing the production process of our products. We must proceed from the actual situation and make comprehensive considerations according to the material, structural characteristics and quality requirements of the castings.

Lost foam casting, also called solid casting, is a model of a foam model with the same shape and shape as the casting. After brushing the refractory paint and drying it, it is buried in the dry sand and is molded under vacuum and under vacuum. The gasification of the model, the liquid metal occupying the position of the model, and the emerging casting method of forming the casting after solidification and cooling, the idea of ​​the process as the core, is still the soul of the industry, which affects the future of the lost foam casting industry and the mold manufacturing industry.

Lost foam casting process

1. Make foam plastic white mold, combined pouring system, gasification mold surface brush, spray special high temperature resistant paint and dry.

2. Place the special compartment sand box on the vibrating table, fill in the bottom sand (dry sand), tap it, scrape the flat, put the dried gasification mold on the bottom sand, fill the dry sand, and shake the appropriate time. Scrape the box mouth.

3. Cover with plastic film, put on the pouring cup, connect the vacuum system to vacuum, dry sand is formed and then cast, the white mold gasification disappears, and the molten metal replaces its position.

4. Release the vacuum. After the casting is condensed, turn the box and remove the casting from the loose dry sand.

Lost foam casting process control

First: the choice of foam beads

1. There are three types of foam beads for foam casting.

(1) Expandable polystyrene resin beads (abbreviated as EPS);

(2) Expandable methyl methacrylate and styrene copolymer resin beads (STMMA for short);

(3) Expandable polymethyl methacrylate resin beads (abbreviated as EPMMA).

2. Commonly used expandable polystyrene resin beads (EPS) for casting non-ferrous metals, gray iron and general steel casting.

3. bead characteristics: translucent beads, pre-expansion multiple 40 ~ 60, particle size of 0.18 ~ 0.80 亳 m (6 sizes).

4. The particle size of the original bead generally selected is less than or equal to 1/9 to 1/10 of the minimum wall thickness of the casting.

Second: About the production of models

1. Made of foamed beads: pre-foaming – curing – foam molding – cooling out of the mold.

(1) pre-foaming

Before the EPS beads are added to the mold, they are first foamed to expand the beads to a certain size. The foaming process determines the density, dimensional stability and accuracy of the model and is one of the key links. There are three methods for pre-expansion of EPS beads: hot water pre-expansion, steam pre-expansion and vacuum pre-expansion. The vacuum pre-expanded beads have a high foaming rate, and the beads are dried and used more.

(2) ripening

The pre-foamed EPS beads are placed in a dry, ventilated silo for a certain period of time. In order to balance the external pressure in the beads, the beads have elasticity and re-expansion ability to remove the moisture on the surface of the beads. The ripening time is between 8 and 48 hours.

(3) Foam molding

The foamed and matured EPS beads are filled into the cavity of the metal mold, heated, and the beads are expanded again to fill the voids between the beads, and the beads are fused to each other to form a smooth surface, that is, a mold. Cooling must be carried out before the mold is released to cool the model below the softening temperature. After the model is hardened and shaped, the mold can be released. After the mold is released, there should be time for the model to be dry and dimensionally stable. The equipment has two kinds of steaming cylinders and automatic forming machines.

2, made of foam plastic sheet: foam plastic sheet – resistance wire cutting – bonding – model. For a simple model, a foam wire cutting device can be used to cut the foam sheet into the desired model. For complex models, first use a resistance wire cutting device to divide the model into several parts and then glue them into a whole model.

Third: the model is combined into clusters

It is a combination of a self-processed (or purchased) foam model and a pouring riser model to form a model cluster, which is sometimes carried out before the coating, sometimes in the case of a buried shape after the coating is prepared. It is an indispensable process for lost mold (real) casting. Currently used bonding materials: rubber emulsion, resin solvent and hot melt adhesive and tape paper.

Fourth: model coating

The surface of the solid casting foam model must be coated with a certain thickness of paint to form the inner shell of the mold. The role of the coating is to improve the strength and rigidity of the EPS model, improve the surface erosion resistance of the model surface, prevent the surface damage and vibration modeling of the model during sanding and the deformation of the model during negative pressure setting, and ensure the dimensional accuracy of the casting. A commercially available special coating for lost foam casting, which is stirred with water in a paint mixer to obtain a suitable viscosity. The agitated paint is placed in a container, and the model group is coated by dipping, brushing, pouring, and spraying. It is usually applied twice to make the coating thickness 0.5~2mm. It is selected according to the type, structure and size of the casting alloy. The coating is dried at 40 to 50 °C.

Fifth: vibration modeling

We introduce a commonly used modeling method (one of two methods). The process includes the following steps: sand bed preparation – placing the EPS model – sand filling – sealing and setting.

1. Sand bed preparation

Place the flask with the pumping chamber on the shaker and clamp it. Put a certain thickness of bottom sand at the bottom (generally the thickness of the sand bed is above 50~100mm), and the vibration is tight. The molding sand is dry quartz sand without binder, no filling, and no water. The ferrous metal has a high temperature and can be made of coarser sand. The aluminum alloy is made of fine sand. The sand is used repeatedly after being treated. The sand box is a sand box with a single opening, a pumping chamber or an air suction pipe, a lifting or walking mechanism.

2. Place the EPS model

After the tapping, the EPS model group is placed according to the process requirements, and the sand is fixed.

3. Sand filling

Add dry sand (several sanding methods) and apply vibration (X, Y, Z directions) for 30~60 seconds, so that the sand fills all parts of the model and increases the bulk density of the sand.

4. Sealed stereotypes

The surface of the sand box is sealed with a plastic film. The vacuum pump is used to draw a certain vacuum into the sand box. The sand is “bonded” together by the difference between the atmospheric pressure and the pressure inside the mold to keep the casting process from collapsing. “Negative pressure setting. More commonly used.

Sixth: casting replacement

The EPS model generally softens around 80 °C and decomposes at 420-480 °C. The decomposition products are gas, liquid and solid. The thermal decomposition temperature is different, and the contents of the three are different. In solid casting, under the action of liquid metal, the EPS model undergoes pyrolysis gasification, generates a large amount of gas, continuously discharges through the coated sand, and forms a certain pressure in the mold, model and metal gap. The metal constantly occupies the position of the EPS model and advances, causing a replacement process between the liquid metal and the EPS model. The end result of the displacement is the formation of a casting. The pouring operation is slow-fast-slow. And keep pouring continuously to prevent the pouring process from breaking. After pouring, the mold vacuum is maintained for 3 to 5 minutes and then the pump is stopped. The pouring temperature is 30 to 50 ° C higher than the temperature of the sand casting.

Seventh: cooling and cleaning

After cooling, the real casting sand falling is the simplest. The sand box can be slanted out of the casting or the casting can be directly hoisted from the sand box. The casting is naturally separated from the dry sand. The separated dry sand is treated and reused.
The above is the introduction of the lost foam casting process.

Large cylinder diameter wet diesel engine cylinder liner (≥φ125), usually used for single casting. According to the traditional mold design process, the produced blank is heavier, the casting cost is higher, and the machining allowance is large. Therefore, it is imperative to reduce the weight of the cast blank and thus reduce the machining allowance.

Before the improvement, the inner hole design of the mold, the traditional design is a diagonal line from the big end to the small end of the mold. This design makes the coating performance of the coating better, the cooling speed of the blank is uniform, and the big end and small end quality of the blank are produced. More uniform. However, due to the limited design, the slope is not too large (otherwise, the coating performance of the coating is poor, resulting in waste), so the processing margin of the produced blank is large.

After the improvement, there are three steps from the big end to the small end on the inner hole surface of the mold. Therefore, there are three steps in the outer round surface of the blank, which are substantially the same as the outer circular surface of the finished cylinder sleeve, so that the blank The machining allowance and weight are greatly reduced.

After the cylinder liner centrifugal casting mold was changed, we found two problems:

1. The wall thickness of the small end of the blank is reduced. When pouring, the cooling rate of the molten iron is accelerated, and the graphite form does not meet the standard requirements.

2. At the large end of the blank, due to the large step difference below the supporting shoulder, the speed of the molten iron in the solidification process is different, and it is easy to produce shrinkage on the inner hole surface of the blank.

Casting mold process adjustment:

Through the implementation of the second incubation process and the adjustment of the casting process, the qualified products are successfully produced. The second inoculation treatment process, before the pouring of molten iron, under certain conditions (such as a certain superheat temperature, a certain chemical composition, a suitable addition method, etc.), a certain amount of substance (referred to as an inoculant) is added to the molten iron. In order to change the solidification performance of the molten iron, improve the as-cast structure, and thereby achieve the purpose of improving the performance of the treatment method, said the inoculation treatment.

The purpose of the inoculation treatment is to promote graphitization, reduce the tendency of white mouth; improve the uniformity of the section; control the morphology of graphite, reduce the formation of D, E type symbiotic graphite and ferrite to obtain medium size A type graphite.

After the mold change is analyzed, the wall thickness of the small end of the blank is thinned, and the cooling rate of the molten iron is accelerated. During the solidification process, the degree of supercooling of the molten iron (0 T) is increased, and the transformation from ΔT1 to ΔT2 and ΔT3 causes the graphite structure to become smaller. It is tapered and transformed from type A graphite to type B, D, and E graphite. In addition, due to the long casting route, 12 sets of molten iron should be poured into 12 centrifugal casting machines, and the pouring time is relatively long. Obviously, a single inoculation process can no longer meet the quality requirements. A second inoculation process must be carried out, that is, an appropriate amount of inoculant is added to the small pouring bag before the centrifugal pouring machine. This treatment method, from the melting of the inoculant to the pouring time is very short, maximizes the role of inoculant, reduces the decline of pregnancy, in the actual production, the rational choice of the size and amount of inoculant is the key to success.

Adjustment of the casting process of the centrifugal casting machine to eliminate shrinkage:

The reason for the formation of the shrinkage is various, and the most fundamental reason is that when the molten iron in the shrinkage portion is solidified, the shrinkage is not obtained. After the casting mold structure is changed, the step of the large end of the blank supports the shoulder. Because the wall thickness of the blank differs greatly, the solidification speed of the molten iron is different, and the molten iron at the thin wall first solidifies, causing the molten iron at the thick wall after solidification to solidify. Feeding, forming a shrink.

Therefore, for the reasons of shrinkage formation, after repeated experiments, the following countermeasures are taken: increasing the rotational speed of the centrifugal casting machine (N); appropriately extending the rotation time of the centrifugal casting machine (TI); appropriately extending the molten iron from the small pouring bag to the pouring Machine pouring time (T2). Through calculation, it is found that there is a mathematical correspondence between (N) . ( T1 ) . ( T2 ) and the blank inner diameter (D). That is, the inner diameter (D) of the blank and the rotational speed (N) of the mold are proportional to each other; and the relationship between the rotation time (TI) of the mold and the casting time (T2). When the inner diameter of the blank is constant, if the actual rotation speed of the mold is lower than the theoretically required rotation speed of the mold corresponding to Fig. 8, shrinkage will occur; similarly, if the actual rotation time of the mold (T1), the pouring time (T2) is lower than the theoretically required rotation time (TI) of the mold corresponding to Fig. 8, and the shrinkage is also generated when the pouring time (T2).

Cost reduction:

The improved liner blank has a reduced wall thickness and a reduced weight, which saves the casting raw materials. At the same time, due to the reduction of machining allowance, the machining tool wear is reduced and the service life is prolonged. With an average weight loss of 3.6 per blank, the tool can save 0.02 yuan / piece. Since the improvement of the cylinder liner was put on the market, it has been more than a year since the production of a large cylinder bore diesel engine cylinder casing of about 50,000. The raw materials and tools saved a total of 614,000 yuan, reducing costs and improving economic efficiency.