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1、消失模铸造存在的技术问题（Technical problems in EPC Process）Problems in lost foam casting / Countermeasures2009-3-25 23:15:00EPC process and products with good appearance quality, high precision, low labor intensity and good working environment in China foundry industry has been used well, especially in recent y
2、ears, domestic manufacturers and technical personnel continue to develop in the raw materials and process equipment, the process of the basic realization of localization, and further promote the EPC Process, the development of technology.The name and type of casting or EPC casting, intuitively namel
3、y: foam model embedded in dry sand vacuum formed casting iron liquid injection, of course to good use of this technology to produce excellent products, should also be good to handle the following problems.Study on forming principle of cut and lost foam casting1. basic requirements for forming of EPC
4、 in dry sandPyrolysis characteristics of 2. foam model3., dry sand, lost foam casting, molding sand filling and compaction characteristics4. filling and replacement of liquid metal by dry sand lost foam casting5. dry sand; lost foam casting; casting; solidification characteristics6. cooling characte
5、ristics of foundry castings with dry sand and their effects on microstructure, properties and residual stresses of cast ironTwo. Development of common technology for EPC process of dry sand1. design and manufacturing technology of foam mould for EPC(1) the function, requirement and manufacturing pro
6、cess of foaming mould;(2) design of foam model (block)(3) design of foaming mould (mould type, module number, module parting surface, structure design, cavity design, vent hole, feeding port, die making mechanism, positioning)(4) foam mold processing;(5) die assembly adjustment;(6) test die for foam
7、ing mould;(7) the rapid manufacture of foaming mould2. manufacturing technology of EPC foam plastics model(1) model properties and selection of raw materials(2) foaming technology(3) curing technology(4) die forming technology;3. coating and coating requirements and basic composition(1) requirements
8、 and basic composition of EPC coating(2) model brushing method;(3) coating drying;4. micro vibration molding technology(1) the requirement of EPC for dry sand molding;(2) modeling key equipment and tooling - vibration table and sand box(3) molding process parameters5. negative pressure casting techn
9、ology(1) technical requirements for pouring;(2) development of vacuum system(3) negative pressure casting process parametersThree 、 lost foam casting raw and auxiliary materials1. foam model raw material - expandable resin beads(1) the requirement of model material for EPC(2) the structure and prope
10、rties of the expandable resin(3) domestic varieties of resin beads2. model adhesive adhesive material3. model surface patches4, the choice of commercial coatings5. molding sandFour, dry sand disappeared Hou casting equipment and workshop designA complete set of expendable pattern casting equipment h
11、as been developed, with specialized suppliers(1) die making equipment - hair generator and molding machine(2) model bond machine;(3) coating and coating preparation equipment(4) molding equipment - various vibrating and sand adding devices(5) sand falling equipment - all kinds of dumping and sanding
12、 devices(6) sand treatment equipment - sand screening, cooling equipment and molding sand conveying equipment(7) negative pressure pouring equipment(8) environmental protection equipment - dust removal system equipment, pouring tail gas purification deviceFive, process levelMinimum weight 0.2kg, max
13、imum weight 500kg, minimum wall thickness 3.5mm, minimum hole Phi 8, dimensional accuracy OBCT8, weight accuracy GBCT8, surface roughness Ral2.5 mu m, machining allowance 2 - SMMSix. Analysis of casting defects of dry sand lost foam castingOneIn this paper, the casting defects of dry sand lost foam
14、casting are comprehensively analyzed. The four categories, fourteen kinds of casting defects, characteristics, causes, influencing factors and preventive measures are expounded.2. the study of carbon defects peculiar to EPC has accumulated some experience in the prevention of deformation, sand, poro
15、sity and inclusions.3. model quality, coating quality, molding process and pouring process and quality of casting, and influence processDegree.Seven. Application of EPC1. types of casting alloys used:Aluminum alloy, special cast iron (high chromium cast iron, etc.), grey iron, nodular cast iron, special cast steel (high Mn steel, Ni Cr and hot steel), plain carbon steel, low C steel and stainless steel2. typical castings with success:(1) antifriction castings - grinding ball, lining board, hammer head(2) and heat - c
