Low Carbon Modeling Of Patternless Sand Casting Process And Optimization Design Of Composite Mold

The traditional foundry industry is responsible for the production of most metal parts,the casting products cover aerospace,automobile,machine tool and other equipment parts,which is an essential part of the manufacturing industry.At present,the industry has the problem of high pollution and high emission,which makes it difficult to match the sustainable development goal of the manufacturing industry.And the traditional sand mold casting process is limited by the mold forming mechanism,which makes it difficult to meet the requirements of high precision and low cost for rapid production of products.Therefore,it is necessary to accelerate the transformation and upgrading of the traditional foundry industry by adopting patternless casting technologies like 3D sand mold printing and CNC sand mold milling.To address the current situation of lack research on the sustainability of patternless sand casting,this paper puts forward a low carbon evaluation model based on the process of patternless sand casting and optimizes the design of the composite molds.The main research contents are as follows:1.The characteristics of patternless sand casting process and molds are analyzed.Then,combined the property relationships of casting processes and resources demand,the resources demand impact factors can be divided into four parts,which are mold forming methods,mold inherent attributes,mold-casting coupling and casting batch production conditions.It provides a theoretical basis for low-carbon modeling of subsequent process.Among them,several indicators are taken as the basis of low-carbon modeling,such as resources consumption,energy consumption,energy efficiency ratio,carbon emission,carbon efficiency,fully considers the resource utilization and environmental impact of patternless sand casting process.2.The forming methods and material selection methods of the composite mold are analyzed.The process parameters of the composite molds are divided into the independent process parameters of the composite mold,the complementary process parameters of the composite mold and the coupling process parameters of the composite mold,and the optimization design of the coupling process parameters of the composite mold is carried out by particle swarm optimization algorithm.3.A certain type of electrical motor cover casting is taken as research objects in this paper,and the patternless composite molds forming process for the castings is proposed by using traditional pattern modeling,3D sand mold printing and CNC sand mold milling.The casting mold is divided into several modules,and the calculation results of various low carbon indexes in the casting production process with single modeling technology are compared.The sand mold is divided into several modules,and the calculation results of various low carbon indexes in the casting production process with single modeling technology are compared.The experimental results show that the patternless sand casting consumes less resources and can significantly reduce the carbon emission of casting process.Composite molds process has great advantages in improving production efficiency,saving resources and reducing environmental impact.At the same time,all the low carbon indexes of the optimized composite molds were reduced to a certain extent,which verified the feasibility of the optimization method and had certain guiding significance for improving the sustainability of the traditional foundry industry.Finally,the low carbon modeling of patternless sand casting and the optimal design of composite molds are discussed and summarized,and the prospect of the future research is put forward.