Plhaub pwm casting (thermosetting resin-bonded sand molding) ua rau cov kev sib txawv ntawm kev lag luam thiab kev lag luam ntawm cov qauv ntsuab xuab zeb casting thiab peev casting (poob ciab). Nws muab kev tswj kom nruj dua, ua kom muaj kev ncaj ncees ntawm qhov chaw, thiab txo cov kaum sab xis rau nruab nrab - mus rau - siab - ntim cov khoom lag luam hnyav ntawm 0.5 kg thiab 80 kg.
Txheej Txheem Txheej Txheem Matrix
|
Feature |
Plhaub Pwm Casting |
Ntsuab Sand Casting |
Kev nqis peev Casting |
|
Dimensional kam rau ua |
TS EN ISO 8062-3 CT7 - CT9 |
TS EN ISO 8062-3 CT10 - CT12 |
TS EN ISO 8062-3 CT4 - CT6 |
|
Nto tiav (Ra) |
3.2 µm - 6.3 µm ({2}} µin) |
12.5 µm - 25.0 µm ({2}} µin) |
1.6 µm - 3.2 µm ({2}} µin) |
|
Phab ntsa Thickness yam tsawg kawg nkaus |
2.5 hli |
4.0mm ib |
1.5 hli |
|
Draft Angle Requirement |
0.5℃- 1.0 degree |
1.5℃- 3.0 degree |
0℃- 0.5 degree |
|
Economic Production Khiav |
300 - 50,000 pcs / xyoo |
100 - 10,000 pcs / xyoo |
500 - 100,000 pcs / xyoo |
|
Tooling Kev nqis peev |
Moderate (Machined Hlau Qauv) |
Tsawg (Pattern Phaj / Matchplate) |
Siab (Ntau-cavity Ciab Txhaj Pwm) |
Kev tsim khoom
Lub plhaub molding txheej txheem cia siab rau ntawm cov khoom siv cob-coated silica xuab zeb sib tov hu rau cov hlau rhuab los yog cov qauv hlau los ua ib qho tawv, nyias- cov phab ntsa ceramic- zoo li pwm plhaub.
Hlau Qauv Kev Npaj:Matchplate qauv yog CNC- ua los ntawm cov hlau hlau, hlau alloy, los yog siab - tensile aluminium, nrog cov nqi shrinkage meej (feem ntau yog 1.5% - 2.2% nyob ntawm kev xaiv alloy).
Preheating & Lubrication:Cov qauv phaj yog preheated rau 200℃- 320℃(392℃F - 608℃F) thiab sprayed nrog ib tug silicone - raws li parting agent.
Muab pov tseg-Lub thawv plhaub tsim:Cov qauv cua sov yog clamped rau lub thawv pov tseg uas muaj cov silica xuab zeb ua ntej-coated nrog 2% - 5% phenolic resin thiab hexamethylenetetramine (HEXA). Inverting lub thawv exposes cov xuab zeb sib tov rau cov rhuab qauv. Thaum tshav kub kub melts cov resin, ua ib feem ntawm daim tawv nqaij kho (6 hli - 10 hli tuab) li ntawm 10 - 30 vib nas this.
Qhov cub Curing:Unbonded xuab zeb ntog deb ntawm re-inversion. Cov qauv thiab txuas lub plhaub dhau mus rau hauv qhov cub kho (300℃- 450 degree) kom hla tag nrho -txuas cov thermosetting binder.
Ejection & Assembly:Mechanical ejector pins thawb lub plhaub nruj ib nrab ntawm tus qauv. Kev tiv thaiv thiab rub lub plhaub ib nrab yog koom nrog siv cov kua nplaum thermosetting nyob rau hauv siab, koom nrog cov cob qhia - cov xuab zeb cores rau hauv cov kab noj hniav.
Pouring & Shakeout:Cov plhaub taum sib dhos tau muab tso rau hauv cov khoom siv hluav taws xob, txhawb nqa nrog cov hlau txhaj tshuaj lossis pob zeb rov qab los tiv thaiv lub taub hau metallostatic, thiab nchuav nrog cov hlau molten. Tom qab txias, lub plhaub nyias kub hnyiab tawm thiab tawg kom huv si thaum lub sij hawm siv tshuab shakeout.
Cov ntaub ntawv thiab kev specifications
Peb yaj thiab nrum ntau yam ntawm ferrous thiab non{0}}ferrous alloys nyob rau hauv nruj spectral tswj.
Kev xaiv cov khoom & Cov cuab yeej siv tshuab siv
|
Tsev Neeg Khoom |
Common Qib / Standard |
Tensile zog (MPa) |
Yield zog (MPa) |
Elongation (%) |
Hardness Range |
Cov yam ntxwv tseem ceeb |
|
Hlau Hlau (Nodular) |
EN-GJS-400-15 / QT400-15 EN-GJS-500-7 / QT500-7 EN-GJS-600-3 / QT600-3 |
400 - 600 |
250 - 370 |
3 - 15 |
130 - 230 HWB |
High qaug zog lub zog, zoo heev damping, tsis tshua muaj siab rhiab heev |
|
Grey Cam khwb cia hlau |
EN-GJL-200 / HT200 EN-GJL-250 / HT250 EN-GJL-300 / HT300 |
200 - 300 |
N/A (Brittle) |
0.3 - 0.8 |
160 - 250 HWB |
Superior thermal conductivity, siab hnav tsis kam, vibration absorption |
|
Carbon Steel |
ASTM A27 Qib 65-35 ASTM A216 WCB/WCC |
485 - 585 |
250 - 275 |
22 - 24 |
140 - 185 HWB |
Weldable structural steel nrog kev cuam tshuam siab ntawm sub- xoom kub |
|
Hlau alloy |
42CrMo4 / AISI 4140 20CrNiMo / AISI 8620 |
700 - 1000 |
550 - 850 |
10 - 18 |
200 - 320 HWB |
Los ntawm -hardenable, tshwj xeeb core toughness, siab hnav tsis kam |
|
Stainless hlau |
AISI 304 (CF8) / 316 (CF8M) 1.4408 / 1.4308 Duplex 2205 (1.4462) |
480 - 650 |
205 - 450 |
25 - 35 |
160 - 220 HWB |
Siab tsis kam rau pitting thiab crevice corrosion nyob rau hauv marine / acid media |
Dimensional Capabilities & Manufacturing Limits
• Qhov hnyav: 0.2 kg txog 80 kg (0.44 lbs txog 176 lbs)
• Maximum Envelope Dimensions: 850 mm x 650 mm x 350 mm
• Linear Tolerances: ISO 8062-3 Qib CT7 rau cov yam ntxwv tsim nyob rau hauv ib nrab pwm; CT8 hla cov pwm parting kab.
• Nto Roughness: Standard Ra 3.2 - 6.3 µm; post-shot-blasting Ra 3.2 µm ua tiav.
• Yam tsawg kawg nkaus li -Cast Hole Diameter: Ø 6.0 mm (nyob ntawm qhov tob- rau - txoj kab uas hla<= 3:1).
Yam khoom tseem ceeb
High Surface Quality & Txo Machining Allowances
Fine silica xuab zeb ua ke nrog nyias, zoo li resin binders minimizes pwm nto lis ciam indentation. Raws li - nrum qhov chaw nthuav tawm Ra 3.2 - 6.3 µm, tso cai rau lub ntsej muag sealing, tsis yog - cov ntaub ntawv tseem ceeb, thiab cov dej ntws ua haujlwm raws li - nrum yam tsis muaj milling lossis tig.
Tight Dimensional Consistency hla ntau lawm Batches
Vim tias lub plhaub pwm raug kho ntawm cov cuab yeej siv hluav taws xob kub, pwm deformation los ntawm cov xuab zeb compaction rog raug tshem tawm. Dimensional repeatability hla ntau- txhiab- feem ntau cov khoom siv feem ntau tuav hauv ± 0.3 hli ntawm qhov ntev txog 100 hli.
Txo qhov hnyav ntawm nyias-Pab phab ntsa
Rigid, siab - tensile plhaub pwm tiv thaiv metallostatic siab yam tsis muaj phab ntsa deflection thaum lub sij hawm nchuav. Cov neeg tsim qauv tuaj yeem hais qhia cov phab ntsa tuab mus txog 2.5 hli, txo cov khoom hnyav thiab cov nqi raw khoom.
Yam tsawg kawg nkaus Draft Angles
Draft cov ces kaum tsawg li 0.5℃mus rau 1.0℃tuaj yeem kos tau zoo yam tsis muaj cov phab ntsa tawg. Qhov no txo cov taper-induced hnyav ntxiv rau ntawm lub hnab ris sib sib zog nqus, tus thawj coj, thiab sab hauv tav.
Tej kev siv
Transmission hloov rab diav rawg
Cav mounting brackets
Nres calipers thiab log hubs
Exhaust manifolds thiab turbocharger vaj tse
Hydraulic valve lub cev thiab manifold blocks
Siab - lub twj tso kua mis thiab lub impeller
Planetary iav carriers thiab bearing vaj tse
Cov yeeb nkab fittings, flanges, thiab npauj npaim valve discs
Taug qab rollers thiab saw sprockets
Hitch Cheebtsam thiab clevis brackets
Hnav daim hlau thiab thoob hniav adapters
Machining thiab Secondary Operations
Txhawm rau xa cov khoom npaj ua ntej- rau- sib dhos cov khoom, peb ua tiav peb cov haujlwm tsim khoom nrog rau tag nrho hauv - CNC machining lub tsev thiab cov chaw ua kom tiav.
CNC Machining peev xwm
• Kab rov tav & ntsug Machining Centers (HMC/VMC): 4-axis positioning nrog pallet changers rau siab - ntim machining ntawm nruj-tolerance bores (± 0.010 mm).
• CNC Turning Centers: Twin- spindle tig rau concentricity- tseem ceeb tig nta, grooving, thiab meej lub ntsej muag sealing nto.
• Kev Ua Haujlwm Thib Ob: Broaching, sib sib zog nqus- qhov drilling, precision sib tsoo (centerless thiab nto), thiab siab - ceev tapping.
Kev kho cua sov
• Normalizing & Annealing: Kev ntxhov siab thiab cov nplej ua kom zoo rau kev ua kom zoo dua qub thiab microstructural homogeneity.
• Quenching & Tempering (Q&T): Kev kho cov cuab yeej cuab tam rau lub hom phiaj tensile zog, toughness, thiab core hardness specifications.
• Induction Hardening: Localized deg hardening (50 - 60 HRC) ntawm hnav lem, iav hniav, thiab bearing cov ntaub ntawv.
Surface Finishes & Tiv thaiv txheej
• Zinc plating (trivalent xiav / ntshiab / daj passivate)
• Electro- txheej txheej (E- txheej) rau kev tiv thaiv corrosion
• Epoxy hmoov txheej
• Phosphating thiab dub oxide conversion txheej
Kev Tswj Xyuas Zoo thiab Kev Tshawb Fawb
Kev lees paub zoo ua raws li ISO 9001: 2015 thiab IATF 16949 cov cai, txheeb xyuas cov khoom siv raw khoom, kev ncaj ncees sab hauv, qhov ntev ntev, thiab cov khoom siv kho tshuab ntawm cov rooj vag txheej txheem.
Incoming Scrap & Ingot Analysis (Spectrometer)
Melt Chemistry Verification Ua ntej coj mus rhaub
Nondestructive & Mechanical Testing (UT / MPI / Tensile / Hardness)
Qhov Kawg Dimensional Layout (CMM & Optical Scanning)
Chemical & Mechanical Testing
• Optical Emission Spectroscopy (OES): Kev txheeb xyuas tshuaj muaj pes tsawg leeg ua rau txhua qhov cua sov ua ntej tapping.
• Tensile & Impact Testing: Kev ntsuam xyuas kev puas tsuaj ntawm lub zog tawm los, lub zog tensile kawg, elongation, thiab Charpy V-notch cuam tshuam tus nqi ntawm ib qho ntau.
• Kev Ntsuam Xyuas Hardness: Brinell (HBW), Rockwell (HRC), thiab Vickers (HV) kev sim ntawm thaj chaw ua haujlwm.
Tsis yog -Kev Ntsuas Kev Puas Tsuaj (NDT)
• Radiographic Inspection (X-ray): Kev txheeb xyuas cov porosity sab hauv, lub tshuab nqus tsev, thiab kev suav nrog rau ASTM E446 / ASTM E192 tus qauv.
• Kev soj ntsuam Magnetic Particle (MPI): Nto thiab sub-Ntoo tawg nrhiav pom ntawm ferromagnetic cam khwb cia hlau thiab steel Cheebtsam.
• Ultrasonic Testing (UT): Phab ntsa thickness pov thawj thiab kev ntsuam xyuas sab hauv.
• Liquid Penetrant Inspection (LPI): Tsis yog-Magnetic stainless hlau tawg tshuaj xyuas.
Metrology & CMM Inspection
• 3D Coordinate Measuring Machines (CMM): Zeiss CMMs ua haujlwm hauv kev nyab xeeb-cov chaw soj ntsuam rau geometric dimensioning thiab kam rau ua (GD&T) pov thawj tiv thaiv CAD qauv.
• Optical & Laser Profilometry: Automated nto roughness (Ra, Rz) ntsuas thiab 3D contour scanning.
OEM thiab Custom Manufacturing
Peb tsim tshwj xeeb rau OEM cov neeg siv khoom tshwj xeeb, muab qhov kawg - mus rau - kawg kev txhawb nqa los ntawm DFM (Design for Manufacturability) kev soj ntsuam los ntawm cov cuab yeej qauv thiab serial ramp - nce.
Engineering & Prototyping Workflow
• MagmaSoft / ProCAST Solidification Simulation: Kev ntsuas kub thiab dej ntws yog ua tiav ntawm cov ntaub ntawv CAD ua ntej txhawm rau txheeb xyuas qhov muaj peev xwm shrinkage kab noj hniav, txias kaw, thiab xuab zeb yaig aav ua ntej hlau qauv txiav.
• Tooling Design & In-Lub Tsev CNC Milling: Hlau matchplates, core boxes, thiab ejector mechanisms yog tsim los ntawm 3D CAD/CAM thiab milled los ntawm siab - ntom tooling hlau los yog cov cuab yeej steel.
• Ceev Prototyping ntawm 3D Printed Sand Cores: Rau kev sim ua haujlwm ceev, 3D luam ntawv cov xuab zeb cores tuaj yeem ua ke nrog cov cuab yeej siv ib ntus kom xa cov qauv qauv hauv 2 - 3 lub lis piam yam tsis muaj kev nqis peev tag nrho.
• PPAP Theem 3 Kev xa tawm: Cov ntaub ntawv tsim tawm Kev Pom Zoo Cov Txheej Txheem suav nrog ISIR (Kev Tshawb Fawb Kev Tshawb Fawb Txog Kev Tshawb Fawb), Cov Txheej Txheem Flow Diagram, Kev Npaj Tswj, PFMEA, Cov txiaj ntsig Dimensional, Cov Ntawv Pov Thawj, thiab Kev Tshawb Fawb R&R.
Cov neeg yuav khoom yuav tsum muab dab tsi rau RFQ
Muab cov khoom ua tiav engineering tsis pub dhau lub sij hawm xa RFQ kom paub meej cov nqe lus hais, raug cov cuab yeej kwv yees, thiab optimized lub sij hawm voj voog.
3D CAD cov ntaub ntawv:STEP, IGES, lossis Parasolid (.x_t)
2D Drawings:PDF nrog GD&T, tseem ceeb tolerances, machining nyiaj pub dawb, thiab nto tiav specs (Ra)
Khoom Specification:ASTM, EN, DIN, ISO, lossis JIS cov ntaub ntawv qib
Volume & Ntau Qhov Loj:Prototype kom muaj nuj nqis, kwv yees txhua xyoo xav tau (EAU), thiab batch loj
Khoom Muag Khoom:Raws li - nrum los yog tag nrho machined los luam
Kev kho cua sov:Target hardness range (HRC/HBW), case depth, los yog microstructure yuav tsum
Kev tshuaj xyuas & kuaj:NDT cov tseev kom muaj (X-ray, MPI), kev ntsuas siab, thiab CMM tshuaj xyuas cov ntaub ntawv
Finishing & Ntim:Txheej txheej (xim xim, plating, tiv thaiv-cov roj xeb), VCI hnab, thiab cov khoom ntim
Cov lus nug nquag
Q: Yuav ua li cas lub plhaub pwm casting piv rau cov qauv ntsuab xuab zeb casting nyob rau hauv cov nqe lus ntawm tag nrho cov nqi?
A: Cov cuab yeej rau lub plhaub pwm casting yog tus nqi siab dua vim tias cov qauv hlau yuav tsum tau tiv thaiv preheating (200℃- 320℃). Txawm li cas los xij, chav tsev cov nqi tsim khoom feem ntau qis dua rau cov khoom siv nyuaj vim tias muaj kev tiv thaiv nruj (ISO 8062-3 CT7) thiab du nto tiav (Ra 3.2 - 6.3 µm) tshem tawm cov kev ua haujlwm thib ob thiab txo cov nqi seem.
Q: Dab tsi yog qhov tsawg kawg nkaus thiab qhov hnyav tshaj qhov txwv rau plhaub pwm cam khwb cia qhov chaw?
A: Peb cov kab ntau lawm tuav qhov hnyav ntawm 0.2 kg (0.44 lbs) txog 80 kg (176 lbs). Rau qhov ntau tshaj 80 kg, cov tsoos resin xuab zeb casting los yog ntsuab xuab zeb molding feem ntau pom zoo vim lub plhaub rigidity thiab flask sizing txwv.
Q: Lub plhaub pwm puas tuaj yeem tsim cov hollow sab hauv thiab cov geometry nyuaj?
A: Yog. Pre-formed resin- cov xuab zeb cores (ua los ntawm kub- lub thawv los yog txias- lub thawv txheej txheem) muab tso rau hauv lub cope thiab rub lub plhaub halves ua ntej clamping. Qhov no tso cai rau cov kua dej sib xyaw ua ke, cov kab hauv qab, thiab cov hollow chamber raug pov tseg kom raug.
Q: Lub sij hawm txhuas twg yog tus qauv rau cov cuab yeej coj mus kuaj thiab pib xa PPAP?
A: Txheem hlau matchplate tooling thiab thawj cov qauv tsim yuav tsum tau 4 mus rau 6 lub lis piam. Yog tias 3D luam ntawv xuab zeb cores siv rau kev kuaj xyuas tus qauv, cov qauv ua ntej tuaj yeem xa tuaj hauv 2 mus rau 3 lub lis piam. Kev txiav txim ntau lawm yog xa tuaj hauv 4 mus rau 5 lub lis piam tom qab kuaj pom zoo.
