Chapter Two White Area 2.3 Lost-in-matrix Model Manufacturing


Lost Foam Casting A method of producing castings using a foam plastic pattern instead of a traditional pattern. It is different from other casting processes, and the factors that affect the quality of castings are also different. Since the model is an essential consumable in the lost foam casting process, each production of a casting will consume a pattern, so the pattern is the key to the success or failure of lost foam casting. Without a high-quality appearance, it is impossible to produce high-quality castings.

The pattern not only forms the shape and size of the lost mold casting, but also participates in the physical and chemical reactions during casting. Therefore, the appearance not only affects the dimensional accuracy of the casting, but also affects the intrinsic quality of the casting.

After the selection of the original material, the advance process is started. Advance process is very short, from the material to the material is generally not more than 2 minutes. However, the correct grasp of the foaming principle and process of pre-foaming can more accurately control the density and surface quality of pre-foaming. The pre-foaming density is the key and decisive factor affecting the weight of the model, and the correct grasp of the pre-foaming process is a powerful guarantee for the quality of the model and the reduction of casting slag defects.

2.3.1.1Working principle of pre-foaming

Before the resin beads (I. e., the raw material particles) are heated to the softening temperature, the beads are not foamed, only the foaming agent escapes. As the temperature rises to the resin software temperature, the beads begin to soften with plasticity. As the foaming agent in the beads is heated and vaporized to generate pressure, the beads are expanded to form a honeycomb structure that is not connected with each other. Once the cells are formed, the hot gas expands to gradually increase the pressure in the cells and further expand the cells. In the process of cell expansion, the foaming agent also diffuses outward and escapes until the pressure inside and outside of the cell is equal. After cooling, the foamed beads were fixed in size. The preexpansion of the beads is generally carried out in a batch foaming machine. The operating parameters of different pre-generators are different, but the operating process is basically the same. The process is as follows:

Preheating: Preheating is the first work to be done after starting up. According to the selection of original materials (EPS or STMMA), the preheating temperature is determined. The preheating process is to uniformly heat the cylinder to the preheating temperature. If it is a steam pregenerator, the condensed water in the cylinder needs to be removed. The uniform temperature of the cylinder can ensure the uniform advance of the advance material.

Feeding: There are manual feeding and automatic feeding. Manual feeding requires each test of weight. Automatic feeding quantitatively adds the original materials according to the weight sensor or volume. Ensure that the pre-release material with stable density is issued under the premise of fixed parameters.

heating foaming: Heating foaming is a foaming process in which the cylinder pressure is comprehensively controlled by steam heating and electric contact point pressure gauge after adding the original material. Heating, to ensure the pre-release process of pre-release particles, pressure control, to ensure that the pressure and temperature of the cylinder are within a reasonable range, effectively ensuring the uniformity of the size of the pre-foaming particles and the pre-release effect.

Discharge: The discharging is the last action after heating and foaming. The pre-hair machine is discharging after a fixed heating time to ensure the particle density. The discharge shall be clean to prevent secondary advance. The second advance will cause the particles to be too large.

Drying: The pre-release material (steam pre-release machine) just after the pre-release has a high humidity. Under the action of the blower and the heating plate, the surface of the pre-release material is dried and scattered. In this way, the advance material will not cause blockage during transportation.

2.3.1.2 Steam pre-generator

RO-steam pre-generator

The steam pre-generator is mainly heated by steam. When the resin beads (I. e., the original material particles) are heated to the softening temperature by steam, the beads do not foam, but the foaming agent escapes. As the temperature rises to the resin software temperature, the beads begin to soften with plasticity. As the foaming agent in the beads is heated and vaporized to generate pressure, the beads are expanded to form a honeycomb structure that is not connected with each other. Once the cells are formed, the steam heats and expands to gradually increase the pressure in the cells and further expand the cells. In the process of cell expansion, the foaming agent also diffuses outward and escapes until the pressure inside and outside of the cell is equal.

EPS (steam type pre-generator) basic process parameters:

Steam pipeline pressure is controlled at 0.05-0.1MPa (behind the pressure reducing valve)

The expansion chamber should be kept at 85~95 ℃ before feeding.

Heating time in 20~30s

The discharge density is 20-23g/L

Basic process parameters of STMMA steam pre-generator:

The pressure of expansion chamber (advance barrel) of advance machine shall be controlled at: 0.025 ~ 0.045Mpa;

Temperature control: 95~105 ℃;

Advance time is controlled in: 30~70s.

 

Foaming density is generally 18~23g/L

 

Electric PreSteamHair machine

Electric PreSteamThe working principle of the generator is very different from that of the steam pre-generator.SteamThe generator mainly heats the barrel through the electric heating wire on the surface of the barrel. The heating is controlled by the frequency converter to control the power to control the temperature of the barrel. As there is no steam, the humidity in the barrel is very small, and the pre-release material can be basically used directly after it is sent out, so that it can be used as it is used, thus avoiding waste. Due to the use of electronically controlled variable frequency power control technology, the advance density is more stable.

 

Electric PreSteamOperation flow of the transmitter

Parameter setting:

Feeding time: The feeding time refers to the time taken for the original material to be sucked from the discharge bin to the temporary storage tank above the equipment. This length of time is adjusted according to the needs of the material, generally 7-10s.

Feeding time: Feeding time refers to the feeding time from the storage tank to the advance machine advance room each time. By adjusting the length of time can adjust the amount of each advance material.

Preheating time: Heating time before feeding, heat the barrel temperature to the specified temperature under the control of the temperature controller.

Heating time: After the heating time, the temperature of the barrel is kept at the specified temperature under the control of the temperature controller. Due to the large changes in altitude and ambient temperature, the general temperature fluctuates in the range of 200-350s.

Preheating exhaust: After preheating, the pressure increases due to the temperature rise in the cylinder. The exhaust is to release the pressure in the barrel and prevent back spray during feeding.

Stabilization time: After heating, the cylinder is no longer heated, but is accompanied by a natural and stable process of stirring in the stirring barrel in the cylinder.

Decompression time: After stabilization, open the exhaust valve time.

discharge time: After the discharge valve is opened, the feeding fan will pump out the advance material in the advance machine and send it to the curing bin for the set time.

electric steam advance machine:

 

The electric steam pre-generator combines the double heating mode of the steam pre-generator and the electric pre-generator. That is, to ensure that the temperature of the cylinder and the gas temperature in the barrel are within the set temperature range. When the temperature of the cylinder is lower than the specified temperature, the electronically controlled variable frequency heating device will automatically adjust the power for proper heating. When the temperature in the barrel is lower than the specified temperature, the steam pneumatic valve will open and fill the appropriate steam to ensure the internal gas temperature. Through the effective control of the dual temperature, the heating temperature is more stable.

This equipment sets the technology of the most developed foaming equipment in Germany and Japan, and combines the manufacturing experience of more than 30 years of foaming equipment in China. It is an intelligent pre-foaming equipment specially developed for lost foam casting in China. Its characteristics are

1. With a key start function, simple and easy to operate, intelligent operation.

2. The foamed beads are uniform and free of dead particles (cast cancer cells), the surface finish of the white mold is good, the density is uniform, and the step density is small. The water content is low, the casting gas is small, and the back spray is reduced.

3. Greatly reduce the aging time of beads. The water content of steam foaming steam is high, and water enters the inside of beads, which is difficult to dry. The amount of electric steam mixed foaming steam used is small, the water content inside the beads is low, the amount of white mold gasification is small, and casting problems such as pores, slag inclusion, carbon defects, etc.

2.3.1.5 Curing of pre-developed beads

After the pre-shot beads of the steam pre-shot machine are cooled, the foaming agent and water vapor in the cell are cooled and liquefied, so that a vacuum is formed in the hole. During the curing process, air penetrates into the cells, so that the pressure inside and outside the cells in the beads tends to be balanced.

The optimum curing temperature of the main force is 23-25 ℃, and the curing time is related to the moisture and density of the beads and the temperature and humidity of the environment. EPS general curing time in 2-4 hours, S curing warehouse TMMA general curing time in 8 hours.

The curing bin is a special storage bin for pre-foamed beads and can be ventilated and ventilated. General capacity in 1-5m ³, generally made of plastic mesh or stainless steel wire mesh.

2.3.2white mould forming equipment

There are many methods for forming the lost foam pattern due to different heating methods, mainly including the steam cylinder forming method and the press air chamber forming method.

1. steam cylinder molding (commonly known as manual molding)

The white mold with complex mold structure has multiple movable blocks on the left and right or up and down that need to be manually disassembled. The white mold has a large demand, and the white mold does not need to be bonded. After the mature beads are filled with the mold cavity by the gun, they are placed in the steaming cylinder, steam is introduced and the pressure and temperature are controlled. After foaming molding, it is taken out from the steam cylinder, cooled and shaped for demoulding.

Due to the foaming of beads during cylinder molding, the heating steam penetrates into the beads through the air holes, so there is both positive air and air and condensed water between the beads, which requires sufficient time for the air and condensed water to be discharged through the air holes. Therefore, the expansion speed of the steam cylinder molded beads is slow and the time is long. However, the combination and removal of the steam cylinder forming mold is manual operation, which has low production efficiency and is not suitable for mass production.

2. Press air chamber molding method

The molding of the air chamber of the mold press is to fill the pre-foamed bead-size material gun into the mold cavity with the air chamber, the mold is horizontally divided into solid mold and moving mold, and the moving template rises and falls to complete the mold opening and closing action molding. Through the control of the procedural steam pressure and time of the moving and solid mold steam, and then through water cooling to cool the model, the required foam plastic pattern or diaphragm can be obtained after demoulding.

(1) Semi-automatic screw forming machine

EPS foam semi-automatic single screw rod forming machine

Main Features of EPS Foam Semi-automatic Single Screw Rod Forming Machine

The cast iron plate with aging treatment and the 45# steel column with quenching and tempering treatment are adopted. The structure design is reasonable, the strength is good, and the corrosion resistance is good.

Through the motor-belt, worm gear-worm, screw cap-screw drive, both overload protection, and high clamping force.

The use of standard screw pitch can not only ensure the speed but also effectively prevent the middle plate from rising.

The maintenance of this machine is convenient and simple.

Main specifications and parameters

 

Specification and model

Table area (mm) working surface size

Maximum stroke (mm)maximum distance

升降速度(m/min)promotion and demotion speed

Power (KW)

ROCX-Ⅰ-0807

800 × 700

600

1.5

1.1

ROCX-Ⅰ-0907

900 × 700

600

1.5

1.5

ROCX-Ⅰ-0908

900 × 800

720

1.5

1.5

ROCX-Ⅰ-1009

1000 × 930

720

1.5

2.2

ROCX-Ⅰ-1208

1200 × 800

720

1.5

2.2

ROCX-Ⅰ-1210

1200 × 1000

720

1.5

2.2

ROCX-Ⅰ-1310

1300 × 1000

720

1.5

3.0

EPS foam semi-automatic double screw forming machine

Main features of EPS foam semi-automatic double screw forming machine

On the basis of manual screw rod and worm gear pair transmission forming machine, PLC programmable controller, touch screen and photoelectric proximity switch control are adopted, and ruler rod and flexible proximity switch positioning block are provided, which can effectively and simply ensure the adjustment of foam products production, and is provided with time control of steam, water and demoulding, thus making the machine work more stable and reliable and greatly saving the starting time and manpower. Fully improve the quality of foam molding products and comprehensive production efficiency.

Main specifications and parameters

Specifications and models

Specification and model

Worktable area (mm)

Working table surface size

Maximum stroke (mm)

Maximum distance

Lifting speed (m/min)

Promotion & demotion speed

Power (KW)

  power

ROCX-Ⅰ-1310B

1300 × 1000

720

1.5

3.0

ROCX-Ⅰ-1411

1100 × 1100

720

1.5

3.0

ROCX-Ⅰ-1412

1400 × 1200

650

1.5

3.0

ROCX-Ⅰ-1510

1500 × 1000

650

1.5

3.0

ROCX-Ⅰ-1512

1500 × 1200

650

1.5

3.0

ROCX-Ⅰ-1514

1500 × 1400

650

1.5

4.0

ROCX-Ⅰ-1712

1700 × 1200

650

1.5

3.0

ROCX-Ⅰ-1715

1700 × 1530

650

1.5

4.0

ROCX-Ⅰ-2012

2000 × 1200

650

1.5

5.5

(2)Air-cooled automatic sheet forming machine

Equipment cavity specifications: 2040*1240*630(mm) installed power: 9.5KW

Key features:

1. The equipment adopts PLC programmable controller and touch screen to control the automatic cycle procedures of mold opening, mold closing, feeding, heating, heat preservation, air cooling, demoulding, product ejection, etc.

2, set up high-pressure blower suction material, using the "penetration" principle molding; cooling using "circulation convection" wind cooling, low moisture content, high production efficiency.

3, the use of high-quality steel welding, and after heat treatment, so that the machine high strength, no deformation, can withstand the expansion force of high-density products.

4, the use of advanced plate-making process, can adapt to the production of high and low density foam sheet, to ensure internal and external consistency.

5. The die adopts special aluminum alloy plate, which has high heat conduction efficiency, good tensile strength and long life.

Full-automatic lost-form molding machine (high matching)

Product performance and characteristicsCommodity details

1. This product is a special hydraulic forming machine for lost foam, which is controlled by computer and has a relatively high degree of automation. 2. The fast opening and closing speed of the machine is more than 4 times faster than the worm gear screw pair transmission. It has the advantages of fast speed, accurate seam retention, high production efficiency and convenient operation.

 

Advantages of automatic control of molding machine

Since the rise of lost foam casting in China in the early 1990 s, it has made great progress in terms of process technology and equipment optimization. A large number of manufacturers of lost foam equipment have emerged in the market, including some equipment manufacturers, who regard the lost foam casting technology as too simple. They know it and do not know why. They use simple packaging equipment on the market to make lost foam white molds, resulting in various problems such as surface defects, deformation, insufficient strength, insufficient filling, size deviation, etc.

Our company for the particularity of the white die forming of the lost vanishing mold, developed a special equipment for the white die forming of the lost vanishing mold, especially for many manufacturers of low degree of automation, poor production environment and other issues, developed a special automatic control system for the molding machine of the lost vanishing mold, the work intensity is greatly reduced. So that the forming is no longer affected by human factors, greatly improve the yield of finished products. Specific performance is as follows:

Highly intelligent and automated control functions-the use of automatic detection, sensing, regulation, automation;

Unique bead filling system-fast filling speed and good adjustment performance;

Unique shooting gun-can be equipped with up to 6 shooting guns, multi-directional rapid beads filled into the various parts of the model cavity;

Computer operating software-based on computer screen and PLC automatic control, software developed specifically for the process of lost vanishation;

Accurately adjust and control the molding parameters of the white mold model-divide the process of mold clamping, preheating, bead filling, heating, cooling, mold opening and so on into 28 process intervals, and the parameters such as temperature, time, pressure and so on can be optimized and adjusted according to the size, thickness and complexity of the molding model.

Unique high-pressure pulse feeding process-to ensure that all kinds of complex structure of the white mold full deformation;

Improve production efficiency-the perfect combination of the whole system, high production efficiency.

The base plate and feet of our hydraulic forming machine are made of cast iron, which is corrosion-resistant and not deformed.

Performance characteristics and warranty:

1. The formwork of this machine adopts artificial aging steel plate and four guide columns made of 45# steel treated by tempering, which constitute a rigid frame, high strength and corrosion resistance.

2. Hydraulic cylinder differential mode is adopted for transmission.

3. Electrical appliances, pneumatic components and valves are well-known brands at home and abroad, with stable, reliable and long service life.

4, PLC programmable controller and touch screen control, automatically complete a molding process.

5. The digital encoder is used to control the mold clamping size, the deviation of the module is small, and the white mold is smooth to ensure the subsequent process.

6. Realize the feeding mode of automatic material gun from the top plate downward and automatic pulse feeding. Meet the feeding requirements of complex parts. Especially suitable for motor shell white mold manufacturing.

The selection of molding machines should be determined according to the customer's product size and mold specifications. General molding machine conventional model is 1000*800 1200*1000 1500*1200 1800*1300

Special specifications can be customized.

2.3.3 automatic bead conveying and curing system (fuzhidaoci)

After the foamed beads are foamed from the foaming machine, the beads need to be transported to each curing silo for curing. In the past, PVC pipes were used for the transportation of beads, but a large amount of static electricity was generated due to the friction between beads and PVC pipes during the transportation of beads. Static electricity was the culprit of the fire caused by the foam factory. So now basically switch to iron pipes to transport beads. Our company adopts PLC automatic control method to transport beads, which is different from other companies using the original manual switch valve or docking pipe method to transport beads, resulting in foam particles all over the floor, which is not conducive to environmental health, but also caused some waste.

2.3.4Layout and requirements of main steam, water and compressed gas pipelines in the workshop

The arrangement of steam, water and compressed gas main pipes in the workshop directly affects the quality of white mold production. No matter how good the equipment is, if the auxiliary equipment does not keep up with the excellent performance, it is like buying a high-end sports car, and its excellent performance can only be reflected on the highway. The white mold of the lost vanishing mold has high requirements for the appearance, not only the surface is smooth and smooth, the internal fusion of the pattern, the density is uniform, and the amount of deformation is required. Therefore, the stability of steam, water and air pressure is very important. Especially for steam, different pressures and temperatures are different, the flow rate and pressure are high and low, and the external environment is constantly changing, resulting in the white mold in the mold being different from time to time. Although the equipment of our company has the functions of PLC intelligent detection of pressure and control of steam flow into the mold by adjusting the valve switch, due to the large number of equipment, if there are multiple equipment using steam or water at the same time, there will still be waste products due to the flow failure.

It is necessary to install the stop valve at the entrance of each equipment pipeline. If a certain equipment is not used temporarily, the stop valve can be closed to avoid water leakage.

2.3.5 The process of forming the shape of the molding machine.

① closed mold: closed foaming mold

When large beads of packaging material are used, there is often a gap at the parting that is smaller than the radius of the pre-bead. It is beneficial to discharge the compressed air from the air plug and the gap during feeding, which is beneficial to quickly fill the mold cavity with beads; when heated by steam, the air and condensed water between the beads can be discharged from the air holes and the gap at the same time.

When using special beads for lost foam, due to the small diameter of the beads, no gap is left when the mold is closed, and the air and condensed water between the beads can only be discharged from the air plug to the mold cavity. And leaving gaps will make the parting surface produce flash.

② Preheating the mold: Preheating the mold before feeding is to reduce the condensation of steam during bead foaming and shorten the foaming time.

③ Feeding: Open the air outlets of the fixed and dynamic mold chambers, blow the pre-foamed beads into the mold cavity through the feeding port of the mold with a compressed air feeder, and plug the feeding port with a feeding plug after the beads fill the whole mold cavity.

Feeding is the basis of bead foaming molding. If the feeding method is improper, the bead filling in the cavity will be unreal or uneven. Even if the mold and bead are good, it will cause pattern defects. Therefore, the method of feeding is an important process of foam molding process. The following describes 3 methods:

a. Suction material filling

The commonly used feeding method. Using a gun, the beads are sucked into the mold cavity using compressed air. For simple mold cavity, this method is better. However, for more complex molds, the beads cannot completely fill the cavity.

B, pressure suction filling

The positive pressure is applied to the beads during feeding, so that the beads fill the mold cavity and have a certain degree of firmness.

C, negative pressure suction material filling

At the same time of filling and feeding, negative pressure is added to the back of the mold, and the cavity is filled with beads under the dual action of negative pressure traction and compressed air suction.

In order to solve the problem of bead feeding of complex thin-walled pattern, the method of feeding multiple guns at the same time can also be used. For the above various feeding methods, the best effect can be obtained by feeding multiple guns at the same time.

  Fixed mold through steam heating

The steam enters the fixed mold air chamber, enters the mold cavity through the air holes on the mold, and the air and condensed water between the beads are discharged from the driven mold cavity through the air holes on the mold wall.

  Dynamic mold through steam

Steam into the dynamic mold air chamber, through the air hole on the mold into the cavity between the beads and condensed water by the air hole on the mold wall from the fixed mold cavity.

  Fixed and dynamic mode steam

The fixed and movable molds are simultaneously heated with steam and kept at a set pressure for several seconds. The beads are softened by heat and expanded again to fill all the gaps between the beads in the cavity and are bonded to each other into a whole.

  Water cooling

Turn off the steam, and at the same time, pass cooling water into the solid and moving mold air chamber to cool the shaping pattern and cool the mold to the demoulding temperature, generally below 80 ℃.

  Vacuum cooling

Drain the cooling water and turn on the vacuum to further cool the pattern and reduce the moisture content in the pattern.

  Mold opening and demoulding

 

Open the mold on the molding machine, select the appropriate mold taking method, such as water gas superposition, mechanical ejector rod and vacuum suction cup and other devices to take out the pattern.

Precautions during molding

① When selecting the steam pressure, consider the type, specification, pattern structure of the beads, and the way the steam is introduced into the mold.

According to the structural characteristics of the mold, select the appropriate feeding method. Insufficient filling can easily lead to insufficient forming defects, and excessive filling will increase the density gradient of the pattern.

③ Control the heat energy of steam. Superheated air will rapidly expand the beads in the same air plug area, hindering the steam from continuing to diffuse inward. It is better to use slightly superheated steam to penetrate into the beads in a relatively dry state.

④ The time for steam is appropriate. The long time of steam ventilation will cause the appearance to shrink greatly when cooling.

⑤ Cool the pattern immediately after forming. Demoulding cannot be done until the internal temperature of the pattern is also sufficiently cooled. Otherwise, there will be expansion pressure inside the internal pattern, which will cause the pattern to expand and deform.

The actual meaning of each action name of the actual on-site molding machine:

1. Pre-blowing: When the machine starts to close the mold, the solid mold blowing valve and the moving mold blowing valve start blowing (if the process is set to steam pre-blowing, it is the solid mold steam valve and the moving mold steam valve). The blowing time is the time set by the above parameters.

2. Wait after pre-blowing: After the pre-blowing is over, the machine waits for a period of time before closing the mold.

3. Delay before reversal: This parameter is used to offset the inertia effect of the motor. That is, the time to drop after the motor loses power.

4. Feeding gap: the time when the motor stops at the feeding limit and then reverses to produce die seam.

5. Feeding: This parameter is used to set the feeding time of the machine.

6、Feeding interval: This time is useful when feeding multiple times. This parameter does not work for one feed. During the second feeding, there should be a pause for a certain period of time, which is the feeding interval.

7. Secondary feeding: When the feeding is insufficient, secondary feeding can be considered. The following feeding time is the second feeding time.

8. Return: After the feeding is finished, close the feeding valve and the raw materials will return to the silo. This time is the return time.

9. Preheating1: After the feeding is completed, the solid mold steam valve and the mold moving steam valve are opened for preheating. This time is preheating.1Time.

10. Mold clamping: The time from the time when the mold is moved down from the position of the feed gap to the time when the mold is fully closed is called the mold clamping time. Please note that this parameter value is generally set to about 0.5 seconds. Because it is a screw forming machine, if the motor is still running after the mold is moved and locked in place, the motor current will increase rapidly, and the motor will be damaged if the time is too long. Be sure to pay attention during operation!

11. Preheating 2: After the mold is locked, the solid mold steam valve and the mold moving steam valve are opened for preheating. This function is exactly the same as preheating 1, except that the former is performed before mode locking and the latter is performed after mode locking.

12. Number of penetrations: This parameter works when the penetrating heating process is selected as the pressure mode. When the pressure in the membrane comes up, the electric contact pressure gauge reaches the upper limit, which is counted as one penetration. At this time, the steam valve will close, the pressure drop, and so on, until the set number of times, the process in the next step.

13、 Solid film heating: the time of solid film heating when penetrating heating. Start timing when the pressure gauge reaches the lower limit. This parameter is only selected"Time mode" or "simultaneous satisfaction" is only useful. This parameter does not work when "pressure mode.

14. Moving mode exhaust: The setting of this parameter is quite flexible. Generally, when the solid mold penetrates and heats, it is the power-on action of the solid mold steam valve and the solid mold drain valve. In this case, the mold pressure rises slowly. If this parameter is set with a time value, the mold moving drain valve will be electrically closed after the time is over, thus the mold fixing pressure will rise rapidly. If the set time is 0, the mold moving drain valve will be closed at the beginning of mold heating. If the time is set for a long time (exceeding the mold heating time), the mold moving drain valve will not be closed during the whole mold heating process. This parameter is valid regardless of the heating method selected for the process.

15. Moving mold heating: the heating time of moving mold when penetrating heating. Start timing when the pressure gauge reaches the lower limit. This parameter is only useful when "time mode" or "simultaneous satisfaction" is selected on the process selection. This parameter does not work when "pressure mode.

16, solid mold exhaust: the setting of this parameter is quite flexible. Generally, when the mold is moved through and heated, the mold steam valve and the mold drain valve are electrically operated. In this case, the shift pressure rises slowly. If this parameter is set with a time value, the solid mold drain valve will be electrically closed after the time is over, thus the mold moving pressure will rise rapidly. If the set time is 0, the solid mold drain valve will be closed as soon as the mold moving heating is started. If the time is set for a long time (exceeding the mold moving heating time), the solid mold drain valve will not be closed during the whole mold moving heating process. This parameter is valid regardless of the heating method selected for the process.

17. Heating interval: when the process is switched from preheating 2 to penetrating heating, penetrating heating to solid, moving mold heating, and penetrating heating to main heating, the solid mold steam valve, moving mold steam valve and solid mold drain valve all lose power, which is conducive to the release of pressure in the solid mold.

18. Main heating A/B: These two parameters are the main heating time. During the main heating, the solid mold steam valve, the moving mold steam valve, the solid mold drain valve and the moving mold drain valve are all powered. If the pressure is capped, the corresponding steam valve is closed and the electricity is again available after two seconds.

19. Insulation: insulation time of products.

20. Exhaust: decompression time in the mold.

21, solid mold, mold water cooling: product cooling time, this time is very important for demoulding. Whether the water cooling is sufficient is related to the smooth demoulding. This time is not the longer the better, water cooling is too long, but will make the product stick to the mold can not fall off.

22. Solid mold drainage on/solid mold drainage off: These two parameters are used in the water cooling process. Reasonable setting of these two parameters can make water cooling more fully. Its meaning is: water cooling solid mold drain valve open and close the time. The solid mold drain valve is closed, the water level in the mold rises, and the solid mold drain valve is opened, and the cooling water in the mold is discharged. For example, if the opening time of solid mold drainage is set to 5 seconds and the closing time of solid mold drainage is set to 8 seconds, when the water ice process is started, the solid mold drainage valve will be closed for 8 seconds and then opened for 5 seconds, and the opening and closing process will be repeated until the water cooling is finished. If the solid mold drainage valve does not need to be closed during the water cooling process, the solid mold drainage closing time can be set to 0, and the solid mold drainage opening time can be set to a value other than 0 at will. If the solid mold drain valve is closed all the time when water cooling is required, the solid mold drain off time can be set to be greater than the water cooling time. The drainage opening time of solid formwork can be set at will.

23. Movable Drainage Open/Movable Drainage Close: These two parameters are used in the cold process. Reasonable setting of these two parameters can make water cooling more fully. Its meaning is: water cooling time shift mold drain valve open and close time. When the mold removal drain valve is closed, the water level in the mold rises, and when the mold removal drain valve is opened, the cooling water in the mold is discharged. For example, when the opening time of mold moving drainage is set to 5 seconds and the closing time of mold moving drainage is set to 8 seconds, when the water cooling process is started, the mold moving drainage valve is closed for 8 seconds and then opened for 5 seconds, and the opening and closing process is repeated until the water cooling is finished. If the mold moving drainage valve does not need to be closed during the water cooling process, the mold moving drainage closing time can be set to 0, and the mold moving drainage opening time can be set to a value other than 0 at will. If the mold removal drain valve is always closed when water cooling is required, the mold removal drain off time can be set to be greater than the water cooling time. The drainage opening time of the moving mold can be set at will.

24. Mold internal pressure: blowing time of blowing valve before mold opening

25. Pre-mold opening: When opening the mold, the mold is moved to a certain distance before blowing. This period of time is the pre-mold opening time.

26. Solid mold blowing/moving mold blowing: the action time of blowing during demolding.

27、 Secondary demoulding: when the process selects secondary demoulding, the moving mold is lifted for a certain distance, and then the mold is closed again. this lifting time is the secondary demoulding time.

28. Secondary mold: Secondary mold opening is the time to close the mold again.

29、 Mold opening timeout: if the demoulding time exceeds the set time, the system will shut down and give an alarm. This value mainly plays a protective role. It should be set reasonably. It is generally set to be slightly longer than the mold opening time in order to play a protective role. If the time is set too long, the motor protection will be lost.

2.3.6 Interface operation and use

After turning on the power, the motor can enter the main screen as shown in the figure below on the screen:

Click to enter the page

 

The parts that the user can operate in this screen are the reset button in the lower left corner and the function switching button in the right half. After the reset button is pressed, the value of the class output can be cleared. And total production users cannot be eliminated. The counting method of output is modulus, that is, the output value is increased once after the process of mold closing to mold opening is completed. The equipment model has been set before the machine leaves the factory and cannot be modified by the user. In this screen, the button on the right side of the screen is used to switch the sub-screen. After pressing, you can switch to a different function screen, such as the "manual" button, the screen will be transferred to the manual screen. In the manual screen, press the "main screen" button in the lower right corner to return to this main page.

A. Process Indication

When the "flow" screen switch button is pressed in the main screen, the screen shifts to the screen shown in the figure below.

This screen is mainly used to indicate the process steps currently made by the machine. For example, if the current machine is working in the step of "keeping warm", this step on the flowchart will turn black, and at the same time, the time above the box will start counting down, indicating how long this step will need to run. If the machine presses the pause button during operation, the machine will stop in the running step and the time will stop. Please note that when the pause is lifted, the timer will restart and the process will continue to run where it left off.

If the machine presses the pause button during operation, the machine will stop in the running step and the time will stop. Please note that when the pause is lifted, the timer will restart and the process will continue to run where it left off.

Press the manual feeding button in the lower left corner to feed the silo. This function is not required if the silo is not installed.

B. Parameter setting

Press the "Parameter" button in the main screen, and the screen will change to the screen shown in the figure above. Press the "Next" button in this screen, and the screen goes to the second parameter setting screen shown in the following figure. (A total of three pictures)

These three screens are used to set the relevant time parameters during the operation of the machine. The setting of these parameters directly affects the normal production and the quality of the product. The time set here can be displayed in the "flow" diagram.

C, process setting

Click the "Process Settings" button in the main screen, and the screen will turn to the screen shown in the above figure. In this screen, which process you want to select, tap the corresponding option, and the selected process will be displayed in black.

1. Pre-blowing mode: When pre-blowing, you can choose whether to use air pre-blowing or steam pre-blowing.

2. Pre-blowing method: generally choose one-time feeding, and choose two-time feeding when the feeding is insufficient;

3. Preheating 2 mode: When selecting the time mode, the whole preheating 2 step will be transferred to the next step after the time is over, while when selecting the pressure mode, the time will not work, but the next step can only be transferred after the pressure is reached.

4. Heating mode: pressure mode: when penetrating heating, the heating switch of the solid moving mold is realized only by pressure. If the pressure mode is selected, the number of penetrations in the parameter takes effect. The number of penetrations means that the pressure reaches the upper limit when the solid and moving die are heated, which is counted as one. Generally, it can be set to 1 time. Time mode: Time priority mode. Penetration switching is done by time. When the time is reached, the heating of the solid moving mold is switched, regardless of the pressure. The timing start condition is that the pressure gauge reaches the lower limit. Satisfied at the same time: when penetrating heating, if the time condition has been met, the system will wait for the pressure condition to be met, and then switch heating; if the pressure and pressure conditions have been met, it will wait for the time condition to be met. That is to say, heating and switching should be carried out only when the time and pressure conditions are reached. The timing start condition is also the lower limit of the pressure gauge.

5. Penetration mode: when penetrating heating, is it to start with moving mold heating or solid mold heating first.

6. Demoulding method: when the product is not demoulding, secondary demoulding can be selected. In the case of secondary demolding, "secondary demolding" in the parameter setting works. Some models of machines can only be selected once demoulding.

7. Demoulding priority mode: you can select whether mold fixing priority or mold moving priority. This method is mainly to decide whether to blow the solid mold first or blow the mold first when removing the mold.

8. Demoulding with water: If the product is not demoulding well, demoulding with water can be selected. The corresponding water cooling valve is also opened during blowing.

D. intermediate start

Click the "Interrupt" button in the main screen, and the screen will turn to the screen as shown in the following figure:

This screen function is mainly used to select the restart step after the machine is powered off. After selecting the corresponding step, press the start button, and the machine will start to run intermittently from the selected step. If you want to cancel after selecting the intermediate step, you can press the "Cancel Selected Interrupt Step" button at the bottom of the screen to cancel the selected step.

After power off, power on again, you can see which step the current machine is parked in from the bottom of the diagram, and then make a selection.

E Manual operation

Press the "Manual" button in the main screen, and the screen will switch to the screen marked in the above figure. This screen is mainly used to test each valve wiring is correct, the action is normal. During normal operation, it can also be used to monitor the dynamic state of each valve or motor. Before testing, please press the automatic/manual switch button in the screen (at least 1 second). When this button changes to manual state, press the corresponding action button in the screen, the corresponding output point will be displayed in black, indicating that there is action output. Please note: When the automatic/manual switch is made, the process that the machine is running will be aborted.

According to different models, it is divided into single-group gun and double-group gun system. If the picture shows a single-group material gun system, the material gun valve 2 and the material inlet valve 2 on the picture do not work.

2.3.7 Foaming mold

Another important factor affecting the quality of foam molding is the design and manufacture of the mold. Choosing the right mold material and designing the best mold structure can not only improve the quality of the mold, but also reduce the cost of molding.

(1) Foaming mold type

① Steam cylinder mould

1-Upper cover plate 2-Outer frame 3-Fastening bolt 4-Lower base plate (including mold core)

The structure changes with the appearance. Because the steam cylinder mold is manual operation, long production cycle, low efficiency, labor intensity, only suitable for small batch production of foam plastic pattern.

② Foaming mould for air chamber of press

1-mold core 2-upper cover plate 3-mold frame 4-feed inlet 5-lower bottom plate

This mold is also called press air chamber mold, often using up and down or left and right open type of structure. The mold core and the mold frame are respectively fixed on the upper and lower air chambers, and a feeding port is opened at the appropriate position of the mold frame, so that the pre-foamed beads can smoothly fill the cavity, and both the upper and lower air chambers are provided with air inlet and outlet.

(2) Foaming mold design

Mold materials. In the mold production process, the foaming mold is subjected to periodic heating and cooling and works under the conditions of water and steam, so its material properties meet the requirements.

A, good thermal conductivity, conducive to rapid heating and cooling;

B, water vapor and water medium has good corrosion resistance;

c. Sufficient strength to withstand the pressure and heating steam pressure generated when the cavity beads are foamed, and to maintain the stability of the shape and size of the mold.

① Due to the light weight and good thermal conductivity of aluminum alloy, aluminum alloy is generally used to make foam molds. The aluminum alloy mold not only heats and cools evenly during the foaming molding, but also has better processing performance and can meet the requirements of the shape and size accuracy.

② Position of profile and feeding port

Lost foam molds are different from other casting molds. It is necessary to obtain a foam pattern that is close to the true reproduction of the shape of the casting, and all mold designs are subject to some constraints.

The choice of parting surface must be guaranteed in addition to the stiffness and strength. It should also make the mold easy to install, remove and operate. It is beneficial to open the feeding port, facilitate the bead to fill the cavity, and facilitate the pattern to be taken out of the mold.

In general, as far as possible the use of the whole mold, for complex shapes of castings (such as cylinder, valve) can be divided into several parts of the mold or the use of core-pulling combination of mold structure.

The material port design is reasonable

 

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