Casting process design is a core element in ensuring casting quality, production efficiency, and cost control. Its content is systematic and comprehensive, mainly focusing on the formulation of technical solutions and optimization of process parameters during the casting process. The main contents of casting process design are as follows:
1. Selection of Casting Process Method: Based on the structural characteristics, material properties, production volume, and usage requirements of the casting, a suitable casting process is selected, such as sand casting, die casting, investment casting, low-pressure casting, or lost foam casting. Different processes differ significantly in terms of precision, cost, and efficiency, requiring comprehensive consideration.
2. Determination of Pouring Position: The rational selection of the direction and position of molten metal injection into the mold directly affects metal flow, gas discharge, and solidification sequence. The principle is to facilitate feeding, reduce defects (such as shrinkage cavities and porosity), and place the thicker parts close to the riser for feeding.
3. Selection of Parting Surface: The parting surface is the joint surface between different parts of the mold. Its selection should simplify the mold structure as much as possible, avoid lateral concavity, ensure a clear casting outline, and facilitate molding and demolding. Ideally, castings should be located within the same sand mold to reduce the risk of misalignment.
4. Core Design: Used to form the internal cavity or complex geometry of the casting. The core head (the structure that holds the sand core), core support (the metal component that supports the sand core), and venting channels need to be designed to ensure accurate core positioning, sufficient strength, and effective venting.
