Research On Typical Defects In Casting Mold For Glass

With improve living standard, people’s demand for glassware transforms from previoussimplicity and durability to a more diverse, artistic and quick updated one. This change isobvious in the manufacturing of luxurious wine bottle glass. Therefore, requirements forglass molds’quality as well as quantity are rising tremendously. Our current research mainlyfocus on optimizing the casting process for glass mold，which helps improve the existingresin sand performance and eliminate casting defects. Also we try to standardize the gatingsystem and establish the database of pouring system in order to increase the productionefficiency of glass mold.Firstly, the loss of raw sand and resin sand after ignition were measured to determinethe performance of the resin sand reclamation equipment. By adjusting the compositions ofthe curing phenolic urethane resin (PEP-SET resin), the sand mold strength, ignition loss andgas evolution can be measured, and an optimized content will be selected according to theproduction requirement. Currently, the enterprise requires the sand mold strength shouldabove0.65MPa and minimize the ignition loss and gas evolution. Several adjustments aremade by us to improve the resin sand production line:(1) in order to reduce the gasevolution, we set the content of PEP-SET resin as1.2%of the sand weight and the radio ofthe component Ⅰ and component Ⅱ is60:40(summer);（2）considering the actual siteconstraints, we add new sand to reduce the loss on ignition and improve the performance ofthe resin sand production line and regeneration equipment;（3）by increase the resin sandregeneration cooling measures, extend the cooling time, optimize the operation of resin sandproduction line to control the sand temperature below35℃；（4） we also suggest addvibration platform to raising sand compaction rate.Secondly, HZCAE/InteCAST was used to simulate the forming process of currentsingle-box casting. Combining the characteristics of casting process with the simulationresults, the casting process was improved. Our results showed that the casting shrinkagedefects and casting scrap were effectively reduced by changing the gate shape and filter type.The shape changes of iron core could adjust the casting solidification speed of each part, fasten sand mold and increase the capacity of sand mold, which all helped reduce the castingshrinkage and deformation defects.Finally, the glass casting mold was classified according to the material and size，and thegating system for each category castings was standardized. We used HZCAE/InteCAST tosimulate and optimize the forming process, and determined the size and type of gatingsystem corresponds to each category castings. Our database included the casting material,size, gating system and qualified rate, which could facilitate the enterprises preserve andquery the data. The database also can provide suitable gating system for subsequentproduction. The production efficiency can be improved with our system..