Development and Progress of V-process in China
- 1. ChineseTechnology Association of Lost Foam Casting and V-process Casting Development and Progress of V-process Casting in China Huazhong University of Science And Technology State Key Laboratory of Meterials Processing and Die&Mould Technology V-process team：Zhang Jianman, Tu Yiming,Liang Qingmin,Chen Min, Xiong Lingda,Zhu Peng,Ke Hao,Qiao Yun,Yang Junlu,Zhang Yu,Liu Liangcai..... Web:www.xsm-v.com.cn Email：zhangjianman66@163.com Phone:+8613545239290 +86 15907126574 Address:No.1037，Luoyu Road,Hongshan District,Wuhan,Hubei,China
- 2. theory of V-process technique Magdeburg hemispheres experiment pressure difference is key factor for the technique; vaccum pump offers possibility for P-difference
- 4. fundamental equipments for V- process casting vacuum serves as binder material V-process casting: the third generation molding method
- 5. Special Properties and Requsts of V-process 1 no binders but dry sand 2 special film for foaming with high extensibility 3 vacuum serves as binder and needed in the whole process 4 special coating for use and play important role 5 special flasks with double wall and filter pipes 6 vibration with high frequency and low amplitude
- 6. developing history • 1974.huazhong industrial college (now HUST)begun studying for the technique; • 1980~1990.several old line was introduced in china from japan; • 1990~2000.chinese domestic firms start studying and manufacturing V- process equipment;meanwhile EVAfilm and coating for V-process had a big progress in property and cost; • 2000~2010.more firms specially producing V-process equipments ,EVA film and special coating;V-process form great influencement in chinese foundry field; • 2010~now.more and more firms find adventage of V-process and pay more attention to it;it is playing important role on chinese foundry'changing and adjustment; HUST form a team specially for V-process casting studying and application,including equipment,pattern,EVA film,coating,and foundry technique;
- 7. over 500 firms by V-process 77% cast iron 21% cast steel nonferrous alloy large to small cast iron to cast steel to nonferrous alloy even nonmetal castings low level to high grade calculated on 2012,12
- 8. about 200 firms by V-process 75% cast iron 21% cast steel nonferrous alloy market influencement international competition wear resistant casting and nonferrous alloy casting are increasing calculated on 2014,12
- 9. SN firm name casting production 1 Hefei Casting &Forging Factory Counterweight 130,000 tons/year 2 Dingzhou Dongfang Foundry Co. Ltd. Counterweight 120,000 tons/year 3 Fujian Changfeng Axle Manufacturing Co. Ltd Cast steel axle housing 30,000 tons/year 4 Tianrui Group Foundry Co.Ltd Bolster、Side frame 200,000 tons/year 5 SANY Heavy Industry Track Shoes 30,000 tons/year 6 Haimen Qilong Fonudries High manganese steel jaw、Crushing wall 20,000 tons/year 7 The Warm-master(Shandong) Cast Iron Boiler Co., Ltd. Piece cast iron boilers 5000tons/year 8 China Railway Shanhaiguan Bridge Group Co.Ltd High manganese steel turnout 7000tons/year 9 IKK(Dalian)Co.,Ltd. Heat-resistant steel frame material、Trays 2000tons/year 10 Roca (Suzhou) Co.,Ltd. Cast iron bathtub 6000tons/year 11 Fujian Dexin Machinery Manufacturing Co., Ltd. Copper Valve 3000tons/year 12 Wuxi HuaXinXing mould co., Ltd. Aluminum mold 2000tons/year …… ……………… .……….. ……….
- 10. Progress of Equipment ——self-making replace importing semi-automatic and high-automatic V-process molding line over 10 firms specially producing V-process production line in china now 5~7molds/h for counterweight 10molds/h for axle box
- 11. Progress of Key Material EVA film and coating decides the running cost even casting quality and application fields Improvement of EVA film especially elongation and cost contributes to V-process' progress coating quality influnces casting quality and later
- 12. progress of technical study 1·1974 huazhong industrial college(now HUST) professor caowenlong start to study V-process casting and form the initial technique system and a reference book《vacuum molding》; 2·2007HUST professor yeshengping furtherly expanded the study range and promoted the progress of EVAfilm,coating,equipments and application;then edit 《V- process casting photo album》 3·2011 HUST researcher zhangjianman form a studying team specially for V-process and moredetailedly,systematicly; especialy concentrating on casting quality ,production economic ,high-level and automatic molding line and so on;
- 13. Typical Cases——Engineering Machinery Castings gearbox counterweight axle housing
- 14. Railway Castings sideframe frog draw gear bolster
- 15. autobobile parts axle housing axle cover drum brake brake disc
- 16. petroleum machinery castings box pumping unitsupport crank/rocker
- 17. Mining&crushing Machinery Wear-resistant Casting hammer rolling mortar wall jaw plate jaw plate track shoe
- 18. art and life piano framework bathtub dustbin Exterior wall
- 19. public construction tunnel supporting plate manhole cover transporting tube electrical valves
- 20. Metallurgy Machinery coke oven -furnace door electrode charging tray of heat treatmentmold for copper metallurgy
- 21. Reasons for Selection and Application • high accuracy—— net shaping • zero draft • surround side machining allowance cancelled • up plate surface machining allowance be 1/3 before • V-process casting VS sand casting
- 22. Reasons for Selection and Application • high accuracy—— net shaping high dementional accuracy and low machining allowance save cost to a great dgree
- 23. Reasons for Selection and Application • high quality—— good surface quality low coarse improve tired life and assembling accuracy if controlled well,V-process casting surface quality can be good as investment casting
- 24. Reasons for Selection and Application • high quality—— little/noun flaw and low foundry stress for thin wall caststeel casting with complicated structure V-process casting offers better solution than resin sand and sodium silica sand comparing all factors;
- 25. Reasons for Selection and Application • low cost—— request of market competition dry sand no binders ,sand circulation easily and little waste; low labour strength lead low labour cost; low wear make pattern cost low; low environmental cost ........
- 26. Reasons for Selection and Application • environmental —— request of modern industrial no harmful gas and wastes; dust from dry sand and noise from vaccum pump are main pollution factors, but easily controlled; investment for environmental equipments will be low in future foundry shop
- 27. Reasons for Selection and Application ——low labour strength：molding relaxedly and shaking out easily;
- 28. summary -application field of V-process (1)medium-big castings with some quatity previously casted by chemical binder sand especially ester-hardening water glass sand and resin sand,co2 water glass sand adventage:production,cost,environment, labour strength,quality it does not means all of the adventages will be reflected on the same casting,but must have some typical adventages;
- 29. summary -application field of V-process (2)castings with some quatity but still little or dimentional big for high pressure molding line but hand-molding can not offer a good quality; adventage:labour strength,quality production,environment, it does not means all of the adventages will be reflected on the same casting,but must have some typical adventages;
- 30. summary -application field of V-process (3)castings with little even single quatity but have high requests on surface coarse or dementional accuracy or machining; adventage:surface quality,dimentional accuracy,machining,environment, it does not means all of the adventages will be reflected on the same casting,but must have some typical adventages;
- 31. Previous Faults and Setbacks 1lack of right guidence make some improper casting used on V-process 2 variety of casting defects make YIELD low 3 unreliable equipments and materials make production low and quality unstable; 4 neglect of dust-cleaning measures make V-process shop environment bad; 5 speciality like cooling rate of V-process on inner quality has not been payed enough attention
- 32. Expectation and Tendency 1 more study and improvement on casting quality problem 2 develop better film and coating even special risers for V-process 3 high molding-rate line for large production casting 4 high automatic-level shop for little/none workers production 5 environmentol shop with low wastes and polution
- 33. Personal Profile of Team Director Zhang jianman Foundry Engineer Secretary-General of Chinese technological association of Lost Foam Casting and V-process casting Researcher of Huazhong University of Science And Technology State Key Laboratory of Materials Processing and Die&Mould Technology Cell phone:+86 13545239290; +86 15907126574 Fax:+86 027-87558143 Address:No.1037,luoyu road,hongshanDistrict, wuhan,hubei,china;430074 Email:zhangjianman66@163.com QQ:1937943818 Web:www.xsm-v.com.cn