Learn more about furan resin sand production line

In the foundry industry, sand casting is an ancient and widely used process method, especially in the production of steel castings and iron castings parts. Among them, the furan resin sand production line and process have become an essential part of the modern foundry industry with their unique advantages and wide range of applications. The following is a detailed introduction to the furan resin sand production line and process, which aims to help you better understand this process and provide strong support for the company’s foreign trade operations.

1. Overview of furan resin sand

Furan resin sand is a kind of molding sand mixed with furan resin, curing agent, sand and auxiliary materials in a particular proportion. It has the characteristics of high strength, high disintegration, good fluidity and thermal stability. These characteristics enable furan resin sand to eliminate factors that affect the deformation and damage of the mold and casting to the greatest extent during the casting process, thereby improving the surface quality and geometric dimensional accuracy of the casting.

2. Composition of furan resin sand production line

The furan resin sand production line usually consists of multiple processes and equipment, including a pre-molding preparation station, sand mixing and molding station, circulation hardening station, demolding and repairing station, coating and surface drying station, box assembly station, and sand removal station after pouring and cooling. The following is a detailed introduction to each station:

Pre-molding preparation station: This station is mainly used to fix the mold and prepare the sandbox. The mold is fixed in a suitable position through a mold fixing device to ensure that the mold and the sandbox are well-matched, providing a basis for subsequent sand mixing and molding.

Sand mixing and molding station: The sand mixing and molding station is the core part of the furan resin sand production line, which includes a double-arm continuous sand mixer and a three-dimensional vibration table. The double-arm continuous sand mixer can automatically mix furan resin, curing agent and sand in a particular proportion to make resin sand. The three-dimensional vibration table is used to vibrate the resin sand filled in the sandbox to remove bubbles and improve the density and quality of the sand mold.

Flow hardening station: The flow hardening station includes equipment such as transfer vehicles and automatic roller conveyor systems. Through the set flow distance and appropriate flow speed, the resin sand is gradually hardened during the conveying process to achieve optimal curing strength.

Mold removal and mold repair station: Mold removal is for manual operation. It requires the same length of the crane chain during mold removal to ensure that the sand mold and sand core are in a horizontal position to avoid damage to the sand mold. Mold repair is to repair the sand mold further to ensure that it meets the design requirements.

Coating and surface drying station: The coating station includes equipment such as a flow coating workbench and flip crane. The flow coating workbench is used to flow coat the solidified workpiece casting sand mold to achieve efficient coating of the coating. The surface drying station is used to dry the coated sand mold to improve its strength and stability.

Box closing station: The box closing station includes equipment such as mold-closing flip cranes and harmful gas collection devices. The flip crane flips the upper mold, and the upper and lower sandboxes are fastened together with the help of sandbox positioning. At the same time, the harmful VOC volatile gases generated during the mold assembly process are collected and treated in a centralized manner through the harmful gas collection pipeline to reduce pollution to the environment.

Sand drop station after pouring and cooling: This station mainly performs pouring, cooling and sand drop operations. Pour the molten metal into the pouring system and pour it into the solidified resin sand mold. After the metal cools and hardens, perform sand drop treatment and remove the casting.

3. Furan resin sand production process

The production process of furan resin sand includes raw material preparation, resin sand preparation, model making, sand mold preparation, pouring, cooling sand drop, and casting post-processing. The following is a detailed introduction to each step:

Raw material preparation: According to the required resin sand strength, wear resistance, and other performance requirements, select the appropriate type of furan resin and curing agent. At the same time, choose suitable sand materials such as quartz sand, zircon sand, etc., and add some auxiliary materials such as accelerators, retarders, etc., as needed to adjust the performance of resin sand.

Resin sand preparation: Mix furan resin, curing agent and sand evenly in a particular proportion to make resin sand. During the preparation process, ensure that the stirring is uniform and there is no apparent graininess.

Model making: Make the model according to the product drawings to ensure that the model size is accurate and the surface is smooth. The model material can be selected from wood, plastic, metal, etc., depending on the product requirements and cost. The surface of the model needs to be treated, such as applying a release agent, to improve the surface quality of the casting.

Sand mold preparation: Pour the prepared resin sand into the model, fill it evenly and vibrate it to remove bubbles. Let the resin sand solidify at a specific temperature, which usually takes several hours to a day. The solidified sand mold has high strength and stability and can meet the casting requirements.

Pouring: Prepare the pouring system and melt the metal. Pour the molten metal into the pouring system and pour it into the solidified resin sand mold. During the pouring process, pay attention to controlling the pouring temperature and speed to avoid defects such as bubbles and inclusions.

Cooling and sand dropping: After the metal cools and solidifies, sand dropping is carried out. After the resin sand mold is broken, take out the casting and remove the pouring system, such as the gate and slide. Clean the castings and remove the resin sand and casting system residues on the surface.

Casting post-processing: Check the castings to ensure that their size, shape and surface quality meet the requirements. If necessary, repair and polish the castings. At the same time, clean and rust-proof the castings to improve their service life and performance.

4. Advantages and applications of furan resin sand production line

Advantages:

High casting quality: Due to the high strength and good fluidity of furan resin sand, the casting surface is smooth, the edges and corners are transparent, and the dimensional accuracy is high.

High production efficiency: furan resin sand has good fluidity and does not require external equipment to compact the molding sand. At the same time, the drying process can be omitted after the alcohol-based coating on the molding sand core is dried, thereby saving a lot of time and space.

Energy saving: furan resin sand has a high recovery rate from old sand and is easy to recycle, which reduces production costs and pollution to the environment.

Wide range of applications: furan resin sand is suitable for the production of various large cast steel, cast iron parts and castings with complex structures.

Application:

Furan resin sand production line is widely used in rail transit, automobile manufacturing, shipbuilding and other fields. For example, in the field of rail transit, furan resin sand is used to produce key components such as gearbox housings; in the field of automobile manufacturing, it is used to make engine cylinders and other components.

5. Maintenance and care of the furan resin sand production line

In order to ensure the regular operation of the furan resin sand production line and extend its service life, regular maintenance and care are required. Here are some suggestions:

Clean and lubricate the equipment regularly to reduce wear and failure.

Regularly check whether the fasteners of the equipment are loose or damaged, and tighten or replace them in time.

Regularly check whether the electrical system of the equipment is working correctly and ensure that it is well grounded to prevent electrical failures.

Regularly conduct overall inspection and debugging of the production line to ensure coordination between various processes and stable and reliable overall performance.

6. Safety and environmental protection measures for the furan resin sand production line

During the operation of the furan resin sand production line, a series of safety and environmental protection measures need to be taken to ensure the smooth progress of the production process and reduce pollution to the environment. Here are some suggestions:

Strengthen employee safety training and education to improve their safety awareness and operational skills.

Set up obvious safety warning signs and protective measures at the production site to prevent accidents.

Perform safety inspections and maintenance on the production line regularly to promptly discover and eliminate safety hazards.

Equip professional environmental protection equipment such as dust collectors and exhaust gas treatment devices to reduce pollution and harm to the environment.

Strictly abide by relevant national environmental protection laws and standards to ensure the legality and compliance of the production process.

7. Conclusion

In summary, the furan resin sand production line and process have become an essential part of the modern foundry industry with its unique advantages and wide range of applications. Through reasonable equipment configuration and process design, as well as strict maintenance and maintenance measures and the implementation of safety and environmental protection measures, the regular operation and long-term stable development of the furan resin sand production line can be ensured. At the same time, with the continuous advancement and innovation of technology and the continuous changes and development of market demand, the furan resin sand production line and process will continue to be optimized and improved to adapt to more complex and diversified production needs.