采用流线型浇注系统减少能源消耗

Reduced Energy Consumption by Using Streamline Gating Systems

本项工作的主要目的是利用流线型浇注系统的原理减小浇注系统的质量,提高出品率,从而减少对铁液的需求量,降低熔炼能量消耗。实际铸造生产线上的试验证明,应用流线型浇注系统能减少浇注系统的质量。把垂直分型,每箱3个阀体铸件的浇注系统由传统布置改为流线型布置,浇注系统的质量减少了1.1 kg,即减少了20%。在本项试验中,浇注系统由传统的转变为流线型后同时消除了铸件对热处理的需求,这在铸造车间是巨大的能量节约。此外,流线型浇注系统的球铁阀体铸件浇注试验证明,浇注温度从1 400℃降低到1 300℃,铸件未出现冷隔的危险。这可能是因为流线型浇注系统充型速度快以及扇形内浇道有减速作用。本项目还通过玻璃板前铸型试验对上述问题进行了研究。

The main objective in the work presented here is to use the principles of the streamline gating systems to reduce the weight of the gating system relative to the traditional layouts. By reducing the weight of gating system and thereby improving yield, the amount of molten iron needed is also reduced hence reducing the energy consumption for melting. Experiments in real production lines have proven that it is possible to achieve a reduction in the poured weight by using the streamline gating systems. In a layout for casting of three valve housings in a vertically parted mould the weight of the gating system was reduced by 1.1 kg changing from the traditional layouts to the streamline gating systems. This weight reduction corresponds in this case to a 20% weight reduction for the gating system. In the experiments the change in gating system from the traditional layout to the streamline layout removed the need for heat treatment. This obviously means a huge energy saving in the foundry. Furthermore the experiments where valve housings in ductile iron was cast also proved that it is possible to lower the pouring temperature from 1 400 ℃ to 1 300 ℃ without the risk of cold runs. This is possible due to a high flow rate during mould filling in combination with low velocities due to the use of fan gates. All of this has also been investigated in experiments using glass plate fronted moulds.