Development Of Pouring Riser Cutting Machine For Valve Castings

Casting casting riser cutting is a very important process in casting manufacturing,this paper mainly aimed at wuzhong Instrument Co.,LTD.Valve casting riser cutting,the current market common pouring riser cutting machine can not meet the requirements of the company,so it is still artificial handheld casting cutting mode.In the cutting process,workers’ hands are close to the grinding wheel,which is very dangerous due to the lack of adequate safety protection measures.Aiming at this problem,this paper designs a special pouring riser cutting machine for the company,and verifies the feasibility of the machine through field trial cutting test.The main research contents are as follows:(1)Through field investigation,the external dimensions of valve castings produced by Wuzhong Instrument Co.,LTD were mapped and 3d models of castings were established.Castings are mainly divided into castings with horizontal distribution of pouring risers and castings with vertical distribution of pouring risers.The two castings have similar casting risers.The problems existing in the cutting of existing cutting machines are analyzed,the design tasks are clarified,and the research content and technical route of this paper are determined.(2)According to the three-dimensional model of casting,based on the existing casting cutting machine,a special valve casting cutting machine for Wuzhong Instrument Co.,LTD is designed.The machine mainly includes clamping,feeding and cutting three parts,through mutual cooperation for pouring riser cutting.Through the analysis of the existing casting cutting machine,the cutting mode of grinding wheel cutting is determined.The clamping method adopts hydraulic clamping,which can not only provide a larger clamping force,but also use the pressure holding circuit to achieve a longer time of pressure holding and maintain the stability of the system.The feeding part adopts the three-axis motion mode,which can realize the grinding wheel to move the casting in all directions and has wider applicability,and can complete the cutting of the casting type selected by Wuzhong Instrument Co.,LTD.(3)On the basis of the preliminary completion of the structural design of the machine,the clamping part,the feed part and the cutting part and other key parts are designed and checked.In the clamping part,two special clamps are designed for different types of castings,and Solidworks Simulation software is used for statics analysis to determine its reliability.The feeding part adopts the mode of two-axis movement of the table and single-axis movement of the cutting part,which not only realizes the three-axis movement of the grinding wheel relative to the casting,but also makes the overall structure relatively simple,and reduces the cost and failure rate.In the cutting part,unidirectional asynchronous motor drives the grinding wheel to rotate through belt drive,which reduces the vibration in the cutting process through belt drive.Meanwhile,automatic tensioning mechanism is designed to reduce the number of system maintenance.Finally,the protective device and auxiliary tool setting device are designed to improve the function of the cutting machine.(4)Design the hydraulic system and control system.Hydraulic system mainly includes the holding circuit and working circuit,the holding circuit can guarantee the hydraulic pump stop working,and in the process of cutting clamp pressure also can guarantee the stability of the whole cutting process,work offers fixture and the security of power and control circuits,clamp two set of fixture is Shared a hydraulic pump,prevent signals of different frequency causes the damage of hydraulic pump,The control of the safety door and the control of the fixture do not affect each other in use.The control system adopts TC5530 stepper motor controller and G instruction programming control,which reduces the operation difficulty and learning difficulty of cutting machine.(5),after the completion of debugging respectively for two different kinds of castings for cutting experiment,for castings poured riser level distribution,manual cutting and machine cutting pass rate was 100%,the rejection rate is 0%,cutting machine cutting time is 114.15 s,the average castings artificial cutting the average castings cutting time is 90.65 s,Machine cutting efficiency is 79.4%of manual.For castings with vertical distribution of riser,the qualified rate of machine cutting is 75.6%,the rejection rate is 14.4%,and the average cutting time of each casting is 251 s.For castings with vertical distribution of riser,the qualified rate of manual cutting is 96.7%,the rejection rate is 0%,and the average cutting time of each casting is 240 s.The efficiency of machine cutting is 95.6%of that of manual cutting.The pouring riser cutting machine for valve castings reduces the labor intensity of workers and guarantees their personal safety.A single worker can operate multiple cutting machines at the same time,improving production efficiency.The rejection rate and pass rate of the vertical distribution fixture of the pouring riser of valve castings designed in this study can not meet the requirements of the company’s products,and further improvement should be made on this basis.