Automatic Lost Foam Casting Machine Foundry Equipments
China Automatic Lost Foam Casting Machine Foundry Equipments, Find details about China Lost Foam, Casting from Automatic Lost Foam Casting Machine Foundry Equipments
Basic Info.
Warranty
12 Months
Services
Support Overseas Services
Trademark
DEXU
Origin
Qingdao
HS Code
8454309000
Warranty
12 Months
Services
Support Overseas Services
Trademark
DEXU
Origin
Qingdao
HS Code
8454309000
Product Desciption
INTRODUCTION :
Lost Foam is a unique casting process which is ideally suited to the manufacturing of geometrically complex castings . The main characteristic of the process is the use of lost patterns made of polymer foam materials, after mounting one or more patterns on the sprue, the clusters are coated with a water-based refractory coating. then the mold is positioned into the flask, filling quartz sand and compacted by the vibration table. After that the molten metal is poured into the sprue, it decomposes the foam pattern and fills the resulting mold cavity in all its details - the cast part is formed.
Procedure
Pre-expansion ---- Molding ---- Assembly ---- Coating ---- Mold filling ---- Casting ---- Demolding---Fettling ---- Sand processing
THE MOST IMPORTANT PROCEDURAL STEPS ARE EXPLAINED BELOW:
1. Source material for the pattern
This part is very important for lost foam casting casting. We should choose the different materials according to the casting material. When we produce the aluminum die castings, we will choose the expandable polystyrene which contain pentane as blowing agent. But for the production of cast iron and steel parts a copolymer made of EPS and EPMMA is used.
2. Pre-expansion
Due to the incorporation of pentane which act as a blowing agent, polystyrene is expandable. The following is a bead pre-expander with a fluidized bed dryer.
3. Molding
For the actual pattern section production, the pre-expansion EPS beads are blown through a fill gun into a metallic permanent mold by using compressed air. In the mold the beads are bonded after heating and the disired pattern geometry is formed. Please check the molding making process below.
4. Pattern section assemble and mounting of the patterns on a gating system
Due to the segmentation of the complex pattern pattern geometries into simple, these sections have to be assembled to one complete pattern after the foaming and drying processes. After that, the several patterns are mounted on one gating system to be the cluster.
5. Coating of the clusters
By dipping, the mounted clusters are coated with a water-based refractory coating. The coating is about 2mm thick.
6. Mold filling
The coated cluster is then positoned in a flask, the quartz sand is filled by sand raining feeder and compacted by the vibration table. At the end of compaction the cluster is completely embeded in the quartz sand and only the sprue remains uncovered.
7. Casting
A down sprue is placed over the EPS sprue. The molten metal is poured into this downsprue and then flows to the gating system of the foam pattern. The molten metal docomposes the EPS cluster and fills into the mold cavity in all its details. Please check the decomposition process below.
8. Demolding
After the solidification of the molten metal , the castings is formed. we will convey the castings to the next shot step for further cleaning.
9. Sand processing department
After demolding, we need to convey the used sand to processing system to return sand for recycling.
MAIN EQUIPMENTS IN LOST FOAM CASTING PROCESS:
- WHITE AREA: pre-foaming machine, molding machine, automatic binding machine etc.
- YELLOW AREA: drying tunnel kiln, eletric heating, heat collection, steam heating etc
- BLACK AREA: flask, turnover box machine, vibration table, sandbox roller, distributor, negative pressure system etc.
- SAND PROCESSING: shakeout grate, dust cover, vibrating sieving conveyor, chain elevator, cooling equipment, belt elevator, sand temperature regulator, bunker, dust remover etc.
ADVANTAGES OF LOST FOAM :
-without limits- Lost Foam produce complex geometry castings very easily
-dimension accuracy-High dimensional accuracy and low tolerances
-weight reducing -Lost foam enables the creation of thin-walled , filigree cast parts ..
-less machining- Lost Foam is done without a core and without burrs so that there is almost no subsequent finishing work
-optically"1A"- Superior surface quality
-environmentally friendly- Energy efficient casting process with low emissions and closed mould material circulation
-Cost efficient- Economically efficient casting process for prototypes and series casted parts.
USAGES OF LOST FOAM CASTING LINE:
The lost foam casting line is widely used in engineering machinery, automobile, automobile parts, aviation, high speed railway, electricity generation,cement, textile machinery, sanitary plumbing, building etc to produce traction seat, engine block, cylinder head, bent axle, flywheel housing, arm beam, reducer housing, engineering machinery supporting seat, water pump housing and so on.
PACKING AND SHIPPING:
Packing : According your requirement
Shipping : By sea or Multimodal transport
Lost Foam is a unique casting process which is ideally suited to the manufacturing of geometrically complex castings . The main characteristic of the process is the use of lost patterns made of polymer foam materials, after mounting one or more patterns on the sprue, the clusters are coated with a water-based refractory coating. then the mold is positioned into the flask, filling quartz sand and compacted by the vibration table. After that the molten metal is poured into the sprue, it decomposes the foam pattern and fills the resulting mold cavity in all its details - the cast part is formed.
Procedure
Pre-expansion ---- Molding ---- Assembly ---- Coating ---- Mold filling ---- Casting ---- Demolding---Fettling ---- Sand processing
THE MOST IMPORTANT PROCEDURAL STEPS ARE EXPLAINED BELOW:
1. Source material for the pattern
This part is very important for lost foam casting casting. We should choose the different materials according to the casting material. When we produce the aluminum die castings, we will choose the expandable polystyrene which contain pentane as blowing agent. But for the production of cast iron and steel parts a copolymer made of EPS and EPMMA is used.
2. Pre-expansion
Due to the incorporation of pentane which act as a blowing agent, polystyrene is expandable. The following is a bead pre-expander with a fluidized bed dryer.
3. Molding
For the actual pattern section production, the pre-expansion EPS beads are blown through a fill gun into a metallic permanent mold by using compressed air. In the mold the beads are bonded after heating and the disired pattern geometry is formed. Please check the molding making process below.
4. Pattern section assemble and mounting of the patterns on a gating system
Due to the segmentation of the complex pattern pattern geometries into simple, these sections have to be assembled to one complete pattern after the foaming and drying processes. After that, the several patterns are mounted on one gating system to be the cluster.
5. Coating of the clusters
By dipping, the mounted clusters are coated with a water-based refractory coating. The coating is about 2mm thick.
6. Mold filling
The coated cluster is then positoned in a flask, the quartz sand is filled by sand raining feeder and compacted by the vibration table. At the end of compaction the cluster is completely embeded in the quartz sand and only the sprue remains uncovered.
7. Casting
A down sprue is placed over the EPS sprue. The molten metal is poured into this downsprue and then flows to the gating system of the foam pattern. The molten metal docomposes the EPS cluster and fills into the mold cavity in all its details. Please check the decomposition process below.
8. Demolding
After the solidification of the molten metal , the castings is formed. we will convey the castings to the next shot step for further cleaning.
9. Sand processing department
After demolding, we need to convey the used sand to processing system to return sand for recycling.
MAIN EQUIPMENTS IN LOST FOAM CASTING PROCESS:
- WHITE AREA: pre-foaming machine, molding machine, automatic binding machine etc.
- YELLOW AREA: drying tunnel kiln, eletric heating, heat collection, steam heating etc
- BLACK AREA: flask, turnover box machine, vibration table, sandbox roller, distributor, negative pressure system etc.
- SAND PROCESSING: shakeout grate, dust cover, vibrating sieving conveyor, chain elevator, cooling equipment, belt elevator, sand temperature regulator, bunker, dust remover etc.
ADVANTAGES OF LOST FOAM :
-without limits- Lost Foam produce complex geometry castings very easily
-dimension accuracy-High dimensional accuracy and low tolerances
-weight reducing -Lost foam enables the creation of thin-walled , filigree cast parts ..
-less machining- Lost Foam is done without a core and without burrs so that there is almost no subsequent finishing work
-optically"1A"- Superior surface quality
-environmentally friendly- Energy efficient casting process with low emissions and closed mould material circulation
-Cost efficient- Economically efficient casting process for prototypes and series casted parts.
USAGES OF LOST FOAM CASTING LINE:
The lost foam casting line is widely used in engineering machinery, automobile, automobile parts, aviation, high speed railway, electricity generation,cement, textile machinery, sanitary plumbing, building etc to produce traction seat, engine block, cylinder head, bent axle, flywheel housing, arm beam, reducer housing, engineering machinery supporting seat, water pump housing and so on.
PACKING AND SHIPPING:
Packing : According your requirement
Shipping : By sea or Multimodal transport
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