High-efficiency and energy-saving production of Dongguan castings:
Save raw materials and recycle them as much as possible. All the raw materials produced consume energy.
The industrial production of precision casting companies means that the annual output of each forging unit is more than 5,000 tons. Due to the large annual output value of the company and the longer working hours of the melting furnace, allocating the heating energy consumption of the furnace itself to one ton of precision castings can greatly reduce.
Improve the management level and reduce the unqualified rate. For example, for a refinery with an annual output of 5,000 tons, each reduction in the failure rate by 1% is equivalent to the production of 50 tons of refined castings. The energy consumption of one ton can reach 405 kgee, which can save 20 tons of standard coal a year. One ton of refining can save 4kgee.
Choosing reliability design and improving processing technology to develop Dongguan precision casting processing technology won the first place in production rate. Improve the gating system software. Under the premise of ensuring the quality of precision castings, the application of hot thermal insulation gates can generally develop the export rate. If the export rate can be increased from 60% to 70%, energy consumption can be reduced by 14.3%.
Use high compactness molding machine and modern core-making expertise to minimize the quality of castings and reduce processing surplus. In actual use, the high-pressure molding design can reduce the quality of castings by 3%-5% compared with the process molding design, and the general equipment molding design can also maintain a machining allowance of 2-3 mm. Reducing the net weight not only saves energy in the precision casting production workshop, but also reduces the energy consumption in the subsequent production process.
Select energy-saving production technology to effectively produce machinery. For example: Replace clay sand air-dried type with self-hardening resin sand or surface dry type to save the energy consumption of air-dried casting; strict seasoning, determine the appropriate composition of precision cast steel, select a reasonable molding plan, and remove castings in the as-cast state For the plaster or hard particles on the surface, the graphitization annealing process is cancelled; the cast ductile iron is used, and the elongation after fracture is specified to be less than 12% in the as-cast state, and the frequency harmonic oscillation aging processing technology should be selected as far as possible to remove Thermal aging processing technology to reduce ground stress. Learning these will increase the company's efficiency and save costs.