Casting is an important basic forming technology in the equipment manufacturing industry. Aeroengines, spacecraft structural parts and automobile cylinder head covers are the important components of high-end equipment. The manufacturing quality of high-quality and complex castings is an important symbol of the comprehensive national strength of the country.
Under the support of the State 973 Program and 04 Major Projects, in view of the problems of difficult and precise control of the complex and high-quality castings in traditional foundries, problems of low efficiency and lack of flexibility in processes, and high energy and resource consumption, the First Research Institute of Machinery Science and Technology And many other units together to jointly promote the 'complex casting moldless composite forming manufacturing key technology and equipment' project research and development.
'The key technology and equipment for complex dieless composite forming manufacturing' is a complicated manufacturing method of dieless composite forming, which can change the traditional mold turning modeling, greatly shorten the process, efficiently produce high quality castings, and improve the precision of complex castings, so as to promote Casting Technology Development After 10 years of innovative research and tens of thousands of hours of forming test, the project team invented the sand / core flexible extrusion and cutting / printing integrated composite forming process, composite casting and sand molding, sand flexible extrusion Machine, moldless casting precision forming machine, sand / core and casting online detection system, 7 kinds of 15 kinds of key equipment and control software system, created a digital moldless casting Island, built an annual output of 600,000 engine cylinder head digital casting shop ; Broke through the three major technical problems of integrated design of high-quality and complex casting molds, self-adaptability of forming process, and matching of moldless equipment with multiple process steps; realized casting of castings / iron, aluminum / magnesium / titanium alloy Compared with the traditional casting, the time is reduced by 50% ~ 80%, the cost is reduced by 30% ~ 50%, the precision is improved by 2 ~ 3 grades and the weight loss is 10% ~ 20%.
Li Junfeng, Deputy Chief Engineer of YTO China, applied the equipment and technical achievements to the development and manufacture of new products such as wheeled tractors, crawler tractors and diesel engines, and provided feedback to developers in the process of using the equipment so as to further optimize the equipment And stability.Through the promotion of rapid prototyping technology both at home and abroad, the scope of application of this technology has been gradually expanded and better social and economic benefits have been achieved.
The project has been popularized and applied in more than 150 such as the 8th Institute of Aerospace Science and Technology and YTO, and 13 application demonstration bases have been set up in Beijing and Guangxi. The company has produced and sold 106 sets of equipment and exported to Spain to realize the engine cylinder head, Aero-engine casing and more than 3000 kinds of complex castings, with a sales increase of 2.28 billion yuan and a profit of 215 million yuan in the recent three years. It has the following advantages in promoting the development of industries such as aerospace, defense and military, automobile and other industries, safeguarding national defense and promoting the green development of the manufacturing industry Important strategic significance.