Case Analysis of Axle Housing Casting Production by Coated Ceramic Sand Shell Mold Process

Process Overview

The shell casting process has a history of decades, which is mainly used in the casting of cast iron and non-ferrous alloys. In recent years, with the rapid promotion of the application of ceramic sand in the coated sand, the ceramic sand shell casting process has been promoted quickly. Because of its round shape, high refractoriness, neutral and stable chemical properties, high strength and high reuse rate, the ceramic sand shell casting process has been widely used in various casting alloys such as cast iron, cast steel ( including stainless steel ) and so on. It can partially replace the lost wax casting process. The dimensional accuracy of castings can reach CT7 ~ CT6 level, and the surface roughness Ra12.5 is below. It significantly improves the productivity and quality of castings, greatly reduces the cost of castings and reduces the emission of casting waste. It is a new green casting process.

Product Information 

• Name : 20 loader axle housing 

• Weight : 51 kg 

Material : 35 # steel 

• Pouring method : vertical pouring, one pouring and one pouring 

• Sand iron ratio : 1 : 0.68 

• Coated ceramic sand particle size : 100 / 200 mesh

Process characteristics 

1.High quality castings : 

• Good surface quality : Baozhu sand mold is round, high sphericity, excellent filling and permeability, can form a more compact sand mold, so that the surface roughness of the casting can reach Ra ≤ 12.5μm. 

• High dimensional accuracy : The dimensional accuracy of castings can reach CT7 ~ CT6, which can meet the requirements of high precision. 

• High tolerance level : it can make the castings have high dimensional stability in the process of processing and using. 

2.High production efficiency : 

• Short process flow : Compared with wax pattern casting, the coated ceramic sand shell mold process saves complex wax pattern production, assembly and dewaxing steps, which greatly shortens the production cycle. 

• High production efficiency : Jewelry sand shell casting process can significantly improve production efficiency, suitable for mass production. 

3.Low cost : 

• Low material cost : high strength, low crushing rate, high recycling rate, less discharge of old sand, and reduced material consumption. 

• Comprehensive low cost : Compared with wax casting, the coated ceramic sand shell mold process does not require complex wax mold production equipment and materials, which reduces the production cost. 

4.Environmental benefits are significant : 

• No dust pollution : As a green casting sand for environmental protection, ceramic sand has no dust and no silica dust hazard. 

• No solid waste

Comparison of process advantages 

• Compared with wax pattern casting : 

• Efficiency : The wax casting process is complex and the production cycle is long, while the sand shell mold process of the coated ceramic is simple and the production efficiency is high. 

• Cost : wax pattern casting requires a large number of waxes and complex molds, and the cost is high ; coated ceramic sand shell process material cost is low, the comprehensive cost is low. 

• Environmental protection : wax pattern casting may produce waste wax and other pollutants, while the coated ceramic sand shell process has no solid waste pollution. 

• Compared with traditional sand casting : 

• Quality : The surface quality and dimensional accuracy of traditional sand casting castings are low, while the quality of coated ceramic sand shell casting is high. 

Efficiency : The production efficiency of traditional sand casting is low, while the production efficiency of coated ceramic sand shell casting is high. 

Cost : The traditional sand casting material consumption is large, the cost is high, and the coated ceramic sand shell process material utilization rate is high, the cost is low.

Scope of application 

Coated ceramic sand shell mold process is suitable for the production of steel castings, stainless steel castings, such as automobiles, construction machinery and other fields of complex castings. It can meet the requirements of high precision, high quality and environmental protection, and has broad application prospects. 

Summary 

The coated ceramic sand shell mold process is an environmentally friendly and low-cost casting process, which can significantly improve the accuracy and appearance quality of castings. It performs well in the production of steel castings such as 20 loader axle housing, and is an important development direction of the future casting industry.