Casting process design involves the process design of the parts themselves, the design of the pouring system, the design of the feeding system, the design of the air outlet, the design of the cooling system, and the design of special casting processes.
The process design of the part itself involves the selection of machining allowance, pouring position, parting surface, casting process parameters, size tolerance, shrinkage rate, mold inclination, correction amount, negative parting number, etc.
The pouring system is a channel that guides molten metal into the mold cavity. Whether the pouring system is designed reasonably or not has a significant impact on the quality of castings, which can easily cause various types of casting defects, such as insufficient pouring, cold shuts, sand flushing, slag inclusion, inclusions, sand inclusion, and other casting defects. The design of the gating system includes the selection of the gating system type, the selection of the inner gate position, and the determination of the cross-sectional dimensions of each component of the gating system. In addition, the selection of the pouring system is also very important, so how can we choose the correct pouring system?
For mechanized assembly lines and mass production, in order to facilitate production and ensure the quality of castings, the inner gate is generally set at the parting surface of the mold. According to the pouring position and parting surface selection of the casting blank, setting the inner gate at the parting surface of the mold belongs to the "intermediate injection" pouring system. Liquid metal inevitably contains a certain amount of "slag" during the pouring process. In order to improve the slag blocking ability of the pouring system, it is suitable to use a "closed" pouring system.
In the casting process, the design of the casting process has a significant impact on the quality of the casting product, but the selection of the gating system selection method cannot be ignored.
The design of the feeding system is an engineering technique that involves the reasonable design of risers and subsidies to compensate for the volume shrinkage of liquid and solidified solids generated during the solidification process of castings, in order to obtain a sound casting.
The air outlet is used to exhaust the gas in the mold cavity, improve the filling ability of the metal liquid, eliminate the supercooled metal liquid and scum that were first filled into the mold cavity, and can also serve as a sign to observe whether the mold cavity is fully filled.
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