Application of automated casting molding line in foundry for casting production of brake disc castings

In 2018, we customized a horizontal parting automated casting and molding production line with a sand mold size of 900mm X 850mm for a casting enterprise in Yantai, Shandong Province, China. This line is used for batch automated casting and molding of brake disc castings and brake drum castings, replacing traditional manual molding to improve production efficiency, control the qualification rate and yield rate of castings, combine traditional production processes and processes to automate and mechanization casting production reasonably, reduce labor demand and dependence on molding workers, improve casting product quality, and minimize casting production costs, making the enterprise more competitive in the industry; The above is a group photo of the team members of Zoomzu and the person in charge of the casting enterprise, as well as a photo record of the official cooperation agreement signed;

The casting enterprise has already introduced and installed automated green sand processing equipment in the early stages for manual molding of casting sand mixing. During the peak period of labor force in the enterprise, the number of molding workers alone reached about 35; The automated green sand and sand processing line has a mixing and processing capacity of 20T of molding sand per hour, and the casting old sand stored in the old sand bin is 60T, which is alternately used with the 60 tons of sand mold old sand placed in the casting workshop. Due to the user's requirement to use the automated pouring line and conduct 24-hour rotating casting work, there is a significant problem with the high temperature of old sand caused by the small storage volume of old sand and long-term use of molding sand. Therefore, we have improved and added a double disc stirring and cooling equipment for old sand in the design of the green sand automation processing line, which can cool the old sand more quickly and effectively.

After a reasonable design and planning of the casting workshop, we have equipped the casting enterprise with a horizontal parting automated casting molding production line, which automatically places the outer frame and pressing iron of the sand mold, and adopts a hydraulic cylinder push and track conversion device. In terms of pouring design, we have also installed a circular guide rail pouring device for users. After the automated molding machine completes the molding of the sand mold, the workers responsible for melting quantitatively distribute the 150kg capacity iron pouring bags installed on the circular rail through a 500kg capacity iron conversion package. After being allocated to two 150kg capacity pouring bags, two pouring workers simultaneously pour the metal iron into the sand mold quickly, ensuring the pouring temperature of the metal iron while greatly reducing the labor intensity of the pouring workers;

In terms of casting production capacity, users require the ability to automatically shape and pour about 40 sand molds per hour, and make the most of the sand iron ratio to effectively utilize the utilization rate of molding sand; We ultimately used 900mm X 850mm as the size of the sand box for the molding machine. Each sand mold for brake disc castings with a diameter of 380mm can complete the molding of four castings, with a filling port for molten iron in the middle and coated sand as the core inside the mold cavity; The total time for shaping and placing the core is 65-68 seconds per sand mold, so it satisfies the user's shaping speed and provides sufficient time for operators to rest reasonably, as well as keeping the pouring line in a static state for workers to quickly pour;

The automated casting molding effect of brake disc castings, the effect of the mold separating from the sand mold cavity after compaction, and the effect of the sand mold before box closing after placing the coated sand core;

Brake disc coated sand core and brake disc casting rough embryo made by enthusiastic box shooting machine;

The advantage of using horizontal parting and horizontal pouring to produce cast brake disc castings after shot blasting and machining is that it is conducive to the dynamic balance processing of later castings;

Brake drum castings after shot blasting and processed brake drum castings;