Structural composition
Turntable:
The turntable is the core component of the turntable gravity casting machine. It is generally made of high-quality cast steel or high-strength alloy steel. It has sufficient strength and rigidity to carry multiple casting molds and bear the corresponding load during rotation. Its shape is mostly circular, rotating around the central axis. Through precise machining and assembly, the stability and accuracy of the rotation are ensured, so that each station can be accurately positioned.
The size of the turntable depends on the different production scales and casting size requirements. Large turntables can be set up with more stations to improve production efficiency; small turntables are more suitable for producing relatively small castings with higher precision requirements.
Mold installation station:
Distributed on the circumference of the turntable, each station is equipped with a special mold installation structure to firmly fix the casting mold. These installation structures usually have a certain degree of versatility, which is convenient for the rapid replacement of molds of different shapes and sizes to meet the diverse casting production requirements. At the same time, in order to ensure the stability of the mold during the pouring and solidification process, the installation structure will fix and position the mold at multiple points.
Pouring system:
It includes the pouring cup, sprue, runner and entgate. The overall design should fully consider the fluidity of the liquid metal, flow control and the filling effect on the mold cavity. The pouring cup is usually located at a suitable position above the turntable to receive the liquid metal scooped out of the furnace, and then guide the liquid metal through the entgate to enter the mold cavity smoothly and evenly through the reasonably designed sprue and runner to ensure that there will be no defects such as sand flushing, splashing and insufficient pouring during the pouring process.
Some pouring systems are fixedly installed at the corresponding position above the turntable, and some are equipped with movable pouring devices to enable more flexible pouring operations at different stations.
Cooling system:
In order to accelerate the cooling and solidification process of the casting in the mold and improve production efficiency, the turntable gravity casting machine is equipped with a cooling system. Common cooling methods include air cooling and water cooling. Air cooling is to set a powerful fan at the cooling station to blow air on the mold and casting surface to take away the heat; water cooling is to set a cooling water channel inside or around the mold to allow the circulating cooling water to absorb heat.
The control of the cooling system can be adjusted according to factors such as the material and size of the casting, and the cooling speed can be accurately controlled to ensure that the casting has good internal structure and mechanical properties.
Transmission system:
Responsible for driving the turntable to rotate, mainly composed of motors, reducers, couplings, gears, and slewing bearings. The motor provides power, which is transmitted to the gears through the coupling after the reducer reduces the torque and increases the torque. The gears mesh with the slewing bearing installed at the bottom of the turntable, driving the turntable to rotate stably at the set speed and direction, realizing the orderly switching of the workstations. The performance of the transmission system directly affects the operating accuracy and reliability of the turntable, and requires regular maintenance and maintenance.
Control system:
This is the key to the automatic production of the turntable gravity casting machine. Through control devices such as programmable logic controllers (PLCs), the rotation angle, rotation speed, pouring time, cooling time, and the connection between each station of the turntable are precisely controlled. The operator can easily set various parameters through the human-machine interface. The control system can also monitor the operating status of the equipment in real time. Once an abnormal situation occurs, such as the mold is not installed in place, the pouring is overtime, etc., an alarm will be issued in time and corresponding protection measures such as shutdown will be taken.
Working principle
First, the operator accurately installs the pre-prepared casting mold on the corresponding mold installation station on the turntable, and preheats the mold and performs pretreatment operations such as preheating to ensure that it is in a state suitable for pouring.
After starting the equipment, the turntable begins to rotate slowly at the set speed. When the station with the mold rotates to the pouring position, the liquid metal is scooped out of the furnace and smoothly injected into the mold cavity through the pouring system. The liquid metal relies on its own gravity to gradually fill the entire mold cavity along the runner. In this process, the continuity and uniformity of the pouring must be ensured to prevent casting defects.
After the pouring is completed, the turntable continues to rotate, and the poured mold is transferred to the cooling station. The cooling system begins to work, cooling the mold and the casting in it according to the set cooling method and time, so that the liquid metal quickly solidifies into a solid casting. During the cooling process, strict control of the cooling rate plays a key role in the quality of the casting.
After the casting is completely solidified in the mold, the turntable rotates again, so that the mold with the casting reaches the retrieval station. At this time, the operator can manually or through the automatic retrieval device to remove the casting from the mold to complete a complete casting cycle. Subsequently, the turntable continues to rotate, and each station repeats the above operations continuously to achieve continuous mass production.
Application field
Automotive parts manufacturing:
Commonly used in the production of automotive engine cylinder blocks, cylinder heads, wheels and other parts. For example, the automobile engine cylinder block has a complex structure and high requirements for internal quality and dimensional accuracy. The turntable gravity casting machine can produce reliable quality cylinder castings with its stable pouring and cooling control to meet the requirements of high-performance operation of automobiles.
Mechanical manufacturing industry:
It can be used to manufacture various mechanical structural parts, such as large gear blanks, reducer housings, etc. For some structural parts that require good mechanical properties and high dimensional accuracy, the use of a turntable gravity casting machine can effectively ensure the quality of the castings by reasonably selecting casting process parameters, and provide high-quality blanks for subsequent mechanical processing and other processes.
Hardware products field:
Produce blanks for various hardware tools, decorations, etc., such as exquisite metal ornaments, door handles with special shapes, etc. By replacing different molds, a variety of shapes can be achieved to meet the market's requirements for hardware products in terms of aesthetics and practicality.
