A good solution to the problems faced by domestic precision casting products


Release time:

2023-06-20

The level of technology is low, and the quality of precision casting products is poor. 1. The problem of cracks in castings is serious. 2. Large castings have serious segregation and inclusion defects. After the solidification of large steel castings and large steel ingots, there are problems of macro segregation and coarse grains at the root of the riser and the thick section of the casting. 3. The application of simulation software is not popular. Casting process simulation is a necessary part of casting production. In foreign countries, if there is no computer simulation technology, it is impossible to get orders. The level of technology is low, and the quality of precision casting products is poor. 1. The problem of cracks in castings is serious. 2. Large castings have serious segregation and inclusion defects. After the solidification of large steel castings and large steel ingots, there are problems of macro segregation and coarse grains at the root of the riser and the thick section of the casting. 3. The application of simulation software is not popular. Casting process simulation is a necessary part of casting production. In foreign countries, if there is no computer simulation technology, it is impossible to get orders.

  1. The level of technology is low, and the quality of precision casting products is poor. 1. The problem of cracks in castings is serious. 2. Large castings have serious segregation and inclusion defects. After the solidification of large steel castings and large steel ingots, there are problems of macro segregation and coarse grains at the root of the riser and the thick section of the casting. 3. The application of simulation software is not popular. Casting process simulation is a necessary part of casting production. In foreign countries, if there is no computer simulation technology, it is impossible to get orders. The computer simulation of my country's foundry industry started early. Although the development ability of the core computing part is strong, the overall software packaging ability is poor. As a result, mature commercial software development is far behind developed countries. A considerable number of foundry companies are discouraged from computer simulation technology. lack of trust. Although the current situation has improved, there are not many enterprises that have purchased foundry simulation software that can play its role. There is an urgent need for software application training for enterprise employees. 4. The production capacity of ordinary castings is overcapacitated, the manufacture of high-precision castings is still difficult, and core technologies and key products still rely on imports. 5. The machining allowance of precision casting is large. Due to the lack of scientific design guidance, it is difficult for process designers to control the deformation problem based on experience, and the machining allowance of casting is generally 1-3 times larger than that of foreign countries. Large machining allowance, serious energy consumption and raw material consumption of castings, long processing cycle and low production efficiency have become bottlenecks restricting the development of the industry. 6. The gating system design is unreasonable. Due to improper design, there are defects such as air entrainment and inclusions, resulting in low casting yield and pass rate.

  2. The environment is seriously polluted and the operating environment is bad. In my country, except for a few large enterprises such as FAW, No. 2 Automobile, Daqi Dahe, Shenyang Liming Company, etc., which have excellent production equipment, advanced precision casting technology, and basically put in place environmental protection measures, most foundries have production equipment Outdated, backward in technology, and generally seldom take into account environmental issues. In the 1980s, the government adjusted the specialization of small-scale, low-tech, and serious-polluting enterprises to increase the degree of intensification of enterprises, but the extensive characteristics of foundry production have not been fundamentally changed. The environmental problems of my country's foundry industry are also manifested in the excessive consumption of natural resources.

  3. High energy consumption and raw material consumption The energy consumption of my country's precision casting industry accounts for 25%-30% of the total energy consumption of the machinery industry, the average energy utilization rate is 17%, and the energy consumption is about twice that of foundry developed countries. The energy consumption per ton of qualified iron castings produced in my country is 550-700 kg of standard coal, while that in foreign countries is 300-400 kg of standard coal. 500-800 kg of standard coal. According to statistics, the input of materials and energy in the casting production process accounts for about 55%-70% of the output value. The gross weight of Chinese castings is 10%-20% higher than that of foreign countries on average, and the average yield rate of steel castings is 55%, while that of foreign countries can reach 70%. Furnace materials in foundry production are mainly pig iron, scrap steel, coke, limestone, etc., molding sand, and core sand. Mainly for the transportation of raw sand, clay, coal powder, resin and other binders, curing agents, old sand, etc., sand mixing, molding, core making, baking, melting, pouring, cooling, shakeout, cleaning and post-processing, etc. The process, as far as its operation content is concerned, is carried out under mechanical vibration and noise, some are still working during high temperature melting and pouring, some produce pungent smell, and the dust working environment is even worse. The above shows the seriousness of environmental problems in my country's precision casting industry, and the use of high technology to realize green casting is a key issue that needs to be solved at present.