Key Technology and Equipment for Complex Casting of Complex Castings

Foundry is an important basic forming technology in the equipment manufacturing industry. Castings such as aero-engines, spacecraft components, and cylinder heads are important components of high-end equipment. The level of manufacture of high-quality and complex castings is an important symbol of the national comprehensive national strength.

 

Under the support of the National 973 Program and 04 major projects, the General Research Institute of Machinery Science and China has been dragging down the problems of traditional castings, such as complicated and high quality castings, difficult control, low efficiency, lack of flexibility, and high resource and energy consumption. A number of companies have joined forces to advance the research and development of the "key technology and equipment for moldless composite forming manufacturing of complex castings."

 

"The key technology and equipment for moldless composite molding manufacturing of complex castings" is a complex moldless composite molding manufacturing method, which changes the traditional mold molding style, greatly shortens the process, efficiently manufactures high-quality castings, improves the precision of complex casting manufacturing, and promotes Casting technology development. After 10 years of innovative research and tens of thousands of hours of forming tests, the project team invented a sand/core flexible extrusion and cutting/printing integrated composite forming process method, compound casting and sand molding material formulation, sand-type flexible extrusion molding machine, and dieless Foundry precision molding machine, sand/core and castings on-line detection system and other seven types of 15 key equipment and control software systems, created a digital dieless casting island, built an annual output of 600,000 engine cylinder head digital casting workshop; breaking the high Three major technical problems, such as the integrated design of quality castings, integrated molding process, adaptive molding process, and non-molded forming equipment matched with multiple process steps, achieved high-quality manufacturing of castings such as cast steel/iron and aluminum/magnesium/titanium alloys. Compared with traditional casting, the time is reduced by 50% to 80%, the cost is reduced by 30% to 50%, the accuracy is improved by 2 to 3 levels, and the weight loss is 10% to 20%.

 

Li Junfeng, deputy chief engineer of China Toto, applied the equipment and technical results to the development and manufacturing of new products such as wheeled tractors, crawler tractors, and diesel engines, and fed back experience to the developers in the process of use, thus further optimizing the equipment. And stability. Through the promotion of rapid prototyping technology at home and abroad, the application scope of this technology has been gradually expanded and better social and economic benefits have been achieved.

 

The project was promoted and applied in more than 150 locations including the China Academy of Aeronautics and Astronautics and China, and 13 application demonstration bases were established in Beijing and Guangxi; 106 sets of equipment were manufactured and sold, and exported to Spain to realize the cylinder head cover of the engine block. More than 3,000 kinds of complex castings such as aircraft engines are manufactured. The newly increased sales of 2.28 billion yuan and profit of 215 million yuan over the past three years are of strategic significance to promoting the development of industries such as aerospace, defense, military, and automobile, safeguarding national defense security, and promoting the green development of the manufacturing industry.