It is known that the best indicators of universality, providing high quality castings are automatic molding line (APL), which are the “heart” of the foundry. To date, modern apl in most cases are working on “Seyattsu-process (Seiatsu Process), in which the seal of sand-clay mixture is carried by air flow (pulse) with a further hydraulic pressing multiplunger head. In modern foundries apl working simultaneously with the number of sets of equipment from two to ten thousand. In this case, microprocessor control system apl stores in its memory all the technological regimes for each type casts, which makes “Seyattsu process” the modern standard of high quality packing sand-clay molds. apl data require that the application of modern Mixture-based systems of runners “Spidmyuller (Speedmuller), which provide an automatic preparation and adjustment of molding compounds with optimal processing properties.
At the same time, the choice of apl for the modernization of small-scale foundries production poses a very significant question their value. Even the minimal set of apl as a separate pulsed setup for “Seyattsu process with manual manipulation and assembly of the half-forms and the mixer” Spidmyuller “is not less than 1,5-2,0 million euros. Such capital costs often discourage investors, particularly in the case of reconstruction of foundries small output – from 1,5 to 3,0 tons of castings per year. This raises the problem of finding ways sharp decline in capital expenditures for the reconstruction of foundries to improve the quality of castings produced to the level of the modern afl. Based on the foregoing, we propose a new concept for the modernization of foundry small-scale production plants based on modern technologies, providing high quality castings. In recent years the foundry has successfully developed new processes that do not have the versatility and performance, as apl, but provide a good quality casting, successfully competing in foreign markets. Our analysis shows that due to the aforementioned unifying factor in the process of rft and lgm easily integrate into the overall system that will dramatically reduce the cost of equipment and at the same time, greatly expand the range of castings, which can be manufactured from various alloys of two advanced technologies.
It should be emphasized that the application of a vacuum when filling forms of rft and hd, you can use a highly efficient catalytic afterburning of exhaust gases after casting molds, which is practically make such processes environmentally friendly, improving working conditions in the foundry. To ensure the vacuum forms (RFT process) rods, we propose to use the equipment of the cts. In this mixer cts will powered by a total turnover of sand. Common to the rft and the lgm are also shake-out, which reduces to the descents of working sand after removal of the vacuum, as well as the regeneration system of working the sand. significantly reduce equipment costs. This combination in one of three shop Progressive molding processes makes it a versatile, allowing to produce castings of different complexity and different alloys. For example, rft method can produce special castings of stainless mild steel.