The principle, composition, and technical parameters of the Q69 series shot blasting cleaning equipment have been briefly introduced in the text.The working principle and component composition of the cleaning and lifting system have been elaborated.The reasons for insufficient precision adjustment of the old structure have been analyzed and improvement plans have been proposed.A screw rod has been selected as the power mechanism to drive the lifting of the rolling brush which enables the equipment to achieve control accuracy while reducing the production and outsourcing costs of the overall components.
Based on the dust removal problem in the casting workshop, the way to achieve the goal of efficient dust removal at lower costs by renovating existing equipment or adding some small equipment has been discussed.After repeated investigation of the on-site environment, the plan to achieve directional air flow has high feasibility.The dust and smoke have been sent to the desired location through different methods, and then controlled by using of dust collection and dust reduction devices to supplement the collection of dust and smoke.Statistical analysis of the data after installation and implementation shows that this plan can achieve significant dust reduction and removal effects without occupying a large amount of capital investment from the enterprise.In the future, other functions can be designed and researched according to one's own needs, which develops towards automation and intelligence.
Aiming at the problems of low production efficiency, high cost, and high labor intensity in the detection process of block casting blank position, a set of block casting blank position detection device has been designed on the basis of the concept of portability and accuracy, while the device design and use have been discussed in detail.This device can be manually loaded and unloaded by one person, making it easy to operate, which can be accurately detected on site in the workshop.The production cost has been reduced and production efficiency has been improved.
The design process of a casting workshop with an annual production of one million crankshafts has been introduced.The electric furnace has been used to melt molten iron.A shell mold line has been selected with an iron shot cooling and conveying system.The shell has been produced by use of the coated sand hot core process; at the same time, the cleaning process of castings has been introduced.The layout of process equipment in the workshop is reasonable and the logistics is smooth.
Aiming at the problems of unstable operation, high debugging difficulty, and high maintenance cost of the flow inoculation device of PUMA pouring machine after being used for a long time, the existing device structure and characteristics have been analyzed.The vibration conveying method of the original device has been changed to the spiral conveying method, achieving convenient debugging and simple use of the inoculation device.At the same time, manual calibration function has been added to the transformation plan to ensure the operation accuracy and stability of the inoculation adding device.
The structural composition and working principle of a single-hook & three-station hanging shot blasting cleaning machine have been introduced, which has the characteristics of structural optimization and compact layout.It can fully and reasonably utilize the existing workshop site and improve cleaning efficiency.In terms of workpiece cleaning, the ideal cleaning results have been achieved, the production cost has been reduced and the production efficiency has been improved.
With the rapid development of the digital economy, the integration of additive manufacturing and digital twin technologies is an inevitable trend in the digital transformation of high-end manufacturing industry, which has attracted attention from all sectors of society.The origin, definition, and key technologies of additive manufacturing and digital twin technology have been summarized in the text.The system framework and application status of digital twin technology in the field of additive manufacturing have been analyzed.A system technology architecture based on the development of additive manufacturing digital twin products and their industry application requirements have been proposed.The key research directions and key technologies have been elaborated.The development trend and application prospects of additive manufacturing digital twin technology have been explored.This study provides innovative ideas for promoting the integration technology research of digital twins and additive manufacturing, as well as the development of applied products.
Steel slag, as the main solid waste in the metallurgical industry, has a low overall utilization rate in China due to its large output and poor stability.The composition of hot pressed steel slag at Baotou Steel has been introduced in the text.The current main treatment processes and advantages & disadvantages in China have been elaborated, as well as the differences in composition, utilization rate, and main application manufacturers of steel slag under different treatment conditions.Based on the mineral phase and physical properties of steel slag, the current utilization status and usage pathways of steel slag both domestically and internationally have been elaborated, mainly including internal and external circulation of enterprises.Internal circulation of enterprises mainly includes the recycling of waste steel and the use of sintering materials.External circulation of enterprises mainly includes road construction and construction, agricultural fertilizer production and soil improvement, concrete, flue gas desulfurization, carbon dioxide absorption, and functional materials and related fields.In addition, aiming at the shortcomings in the current utilization of steel slag, the future development direction of steel slag has been expected.
Currently the increase of casting capacity is not allowed by the industrial policies which can only be replaced.At the same time, industry restructuring has led to the withdrawal of some casting enterprises from the market.When a casting enterprise terminates its original production and operation activities and changes the nature of its original land use, it is necessary to conduct pollution monitoring, analysis, and evaluation of the soil and groundwater at the original site.In the face of new ecological and environmental management requirements, the preliminary investigation content of the site environment of the casting enterprise has been sorted out, while the investigation area and pollutant determination of the casting enterprise site have been analyzed.Finally, the key points and precautions for the preparation of the preliminary investigation of the site environment of the plot have been summarized.
Aiming at the current issue of synergy between professional experimental teaching and ideological & political education in engineering colleges, taking the course "Basic Experiment of Material Processing" as an example, by introducing cutting-edge experiments in intelligent manufacturing with a student-centered approach, using new educational models such as case explanations and thematic discussions to integrate ideological and political elements, the students' professional literacy and innovative abilities have been effectively cultivated.The interest of students in learning their major has been enhanced, which achieves practical education and value-guided view.
With the increasing emission requirements for engines, the requirements for their components are also increasing, forcing engine manufacturers to update and upgrade the existing platform engines, thus in this way, the development cycle of new products has been required to continuously shortened.The successful application of 3D printing technologies such as sand core printing and nylon printing in the rapid product development process has been introduced.
The joint treatment of 3DP products has been directly related to the appearance consistency and product quality issues of cultural and creative products.The way to choose appropriate joint filling materials and repair processes is the primary content to solve the joint problem of 3DP products.The joint treatment process and method of 3DP products have been briefly discussed in the text.
Two permeability testing methods have been used to systematically compare the permeability of four sand casting water-based coatings.The influence of coating thickness on permeability and the differences in permeability among different coating varieties have been analyzed.The role of coating permeability has been discussed on basis of production practice, which provides reference for strengthening the understanding of casting coating permeability.
By comparing to traditional furan resin for casting, phenolic resin, inorganic resin and other binders have many advantages as the ideal casting binder.However, at the same time, this type of binder has the problem of being difficult to solidify at room temperature.It is necessary to quickly evaporate the moisture inside the binder under high temperature conditions to improve the speed of sand mold solidification.Combining the molding principle and equipment structure of the casting sand 3D printer, the rapid solidification of the sand mold has been considered from the printing equipment itself.The solidification speed of the sand mold has been improved from five aspects∶firstly, increasing the temperature of the adhesive; secondly, increasing the temperature of the sand; thirdly, installing infrared heating lamps on the sand spreader to bake the sand surface to increase the temperature of the sand surface and accelerate the evaporation of moisture in the binder; fourthly, designing a special working box structure with heating coils, during the printing process, as the printing sand molds are continuously stacked, the formed sand molds are continuously heated to quickly improve the solidification speed of the sand molds; at last, controlling the environmental temperature and humidity inside the printing room.
In order to ensure and recognize the chemical composition, mechanical properties, non-destructive testing and dimensional inspection results of steel castings before leaving the factory, the current usual method used is to gather on behalf of the customer's relevant parties at the manufacturer's inspection site, and witness the results through on-site participation, which has a certain impact on the human resources costs and production cycle of the products of all parties.Based on this situation, a remote witness method has been designed, which uses online inspection to achieve the goal of participating in the witness without leaving the house.
As a major foundry country, digitization is a necessary path for China to transform into a strong foundry country.The application of digital technology in the casting process of engine cylinder heads has been explored, in response to common problems in the traditional casting industry such as long product development cycles, difficulty in collecting production process data, and cumbersome quality data analysis.The digital exploration and practical cases in recent years have been introduced in the text, including process research and development, workshop on-site production, and quality improvement, in order to provide reference for digital management in the industry.
The characteristics of SAE J434 D700 material have been introduced, and the influence of chemical composition on the matrix structure has been deeply studied.A casting melting method has been developed by adjusting the ratio of the five basic elements C, Si, Mn, P, S, and alloy elements Mo, Cu, and Sn.The method has been carried out through injection spheroidization treatment and secondary inoculation treatment.After implementation, the SAE J434 D700 material with good performance has been obtained, of which all performance indicators meet the technical requirements.
With the development of the domestic hydro-power industry market, the casting level of integrated casting runners and semi-integrated casting runners has also been correspondingly improved.The traditional Francis turbine runner is usually composed of three parts∶the upper crown, lower ring, and blade.The three parts have been cast separately and welded together after final processing.With the development of casting technology, the mixed flow runner has achieved three integrated casting, successfully solving the problems of high manufacturing cost and low casting quality.
With the increasingly severe environmental protection situation, the requirements for the emission of SO2 in cupola flue gas are becoming stricter.By comparing various desulfurization methods and combining with the actual situation of 35 t/h cupola on-site, the SDS sodium-based dry desulfurization process has been adopted to desulfurize the cupola flue gas and achieve standard discharge.
The advantages, disadvantages, and process control methods of cutting high alloy test blocks with an oxyacetylene cutting torch have been described in the text.By comparing the mechanical performance test results of the test blocks after cold cutting and hot cutting, it is confirmed that the heat generated during the cutting process has no significant impact on the mechanical properties of the test blocks.The oxyacetylene cutting torch cutting method is reliable, which can be promoted and applied by industrial peers.
The classification of wall thickness uniformity of cast pipes and the main reasons affecting wall thickness uniformity have been studied.Based on the actual production situation, by standardizing the production and repair standards for the shape and size of the fan-shaped package, adjusting the fast flipping delay, fast flipping speed, and flipping return delay of the fan-shaped package, increasing the slope of the flow channel on the basis of the original equipment of the centrifuge, and installing cooling equipment at the centrifuge socket to strengthen the cooling of the socket, various measures have been taken to reduce the negative tolerance of the casting pipe and improve the wall thickness uniformity of the casting pipe.It provides certain data support for optimizing the wall thickness uniformity of cast pipes in the future.
Due to various reasons, iron castings may produce many casting defects in production.Welding and repairing castings can improve the yield of castings and reduce production costs.The micro-structure analysis of gray cast iron, nodular cast iron, and vermicular graphite cast iron under cold welding processes of electric spark surfacing and laser cladding has been mainly investigated.The results show that laser cladding has better fusion ability between the base metal and the welding material, and better welding repair quality by comparing to electric spark surfacing; the order of welding repair quality is as follows∶ gray cast iron is better than vermicular graphite cast iron which is better than ductile iron.
