Analysis of Industrial Application of 3D Printing in Casting

3D printing equipment adopts the additive manufacturing technology, which is the method of gradually accumulating materials to produce solid parts. It combines many high-tech advantages such as computer graphics processing, digital information control, laser technology, electromechanical technology and material technology. It is used to improve the product manufacturing process and drastically shorten the R&D and production processes. Among many 3D printing technologies, 3D printing technology (abbreviated as 3DP technology) has the characteristics of high forming speed, low cost of forming materials, etc., and the forming process does not require support. The excess powder material is easily removed, and is particularly suitable for complex prototypes of inner cavities. The most suitable for combination with the casting process to achieve industrial applications.

In 2012, the company introduced imported high-efficiency large-scale 3D printing equipment to carry out industrialized application research of 3D printing technology in casting. The equipment adopts 3DP technology, which is mainly used for the direct printing and forming of foundry sand molds. The four processes of mold making, molding, core making and forming in traditional casting are all replaced by one process of 3D printing. 3DP technology is a technology that builds three-dimensional objects by layer-by-layer printing by using powdery and other adhesive materials based on digital model files. It is a fusion of information technology, materials technology, and digital manufacturing technology. The principle is: the first step, the sand used by the sander is sanded and compacted in layers according to the set amount of sand, and the second step, the print head is printed with a resin binder on each layer of the sand. On the sand layer; the third step, after the “printing” is completed, the lifting platform is lowered by 0.3~0.5mm, the sander is sanded once again, and the printing nozzle is once again “printed”, so that it circulates repeatedly until a complete sand pattern is printed.

In the process of combining 3DP printing technology with the foundry industry, on the one hand, because the purchased 3D printing equipment is imported from abroad, its equipment requires the use of molding sand, resin, curing agent and other materials provided by the equipment manufacturing company, and its 3D printing equipment and sand are patented. In the trial operation stage, the sand, resin, and curing agent used in the original equipment can be used to print out the perfect sand type, but the cost is very high. As a result, the company will be selling at a loss, and it will not meet the development needs of the company. To this end, the technical team began to look for other sand, resin, and hardener materials that can be used for 3DP technology. Through comparison and analysis of the sand particle size, sand content, etc., and the cooperation with related domestic manufacturers, it eventually developed a qualified production. Sand-type domestically produced 3D printing foundry sand; Through the deployment and testing of resin and curing agent, we have developed the amount of resin and curing agent added to domestic sand. Through the localization of raw materials, the cost of the 3D printing sand mold has been reduced by 60%, which has earned the company a certain profit margin. On the other hand, due to the limitations of the current 3DP printing technology, layering problems often occur in 3D printing sand molds. In order to solve this problem, the proportions of resin, curing agent, sand drying method and temperature were studied. Finally, the defect of easy delamination of 3D printing sand type was overcome, the scrap rate of castings was greatly reduced, and the production of 3DP technology was reduced. Casting quality costs.

3DP technology produces castings with the following advantages:

First, shorten the casting production process. The 3DP technology printing and casting sand mold eliminates the time and cost of making sand molds, greatly shortens the development cycle and cost of new products, and seizes opportunities for the company to open up new markets.

Second, improve the quality of castings and increase production efficiency. 3DP technology can print scattered small sand patterns as a whole, avoiding the cumulative errors caused by manual core making and molding in the process of core assembly, improving the dimensional accuracy of sand molds, and avoiding the defects of castings with poor size due to inconsistent sand size. , And save some of the core process.

Third, the design is flexible, cost-saving, and manufacturing difficulty. As the 3DP printing process is a method of transferring digital files into a 3D printing device, the design of the 3DP printing process can be modified flexibly and in a timely manner, and the complicated cavity structure that can not be completed by manual molding can be printed, which reduces the production difficulty.

Fourth, people-oriented, green casting, intelligent casting. 3DP printing technology has greatly improved the environment at the casting site and reduced the labor intensity of the operators. The use of 3D printers instead of artificial cores and styling has saved manpower costs, and at the same time it has achieved smart production and green production in the foundry industry.

The industrialization and application of 3D printing technology in the field of casting will have a transformative significance for the transformation and upgrading of China's foundry industry, the intelligentization of the casting process, and the construction of future foundry smart factories.

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