Design And Simulation Of A Sprue Removal Machine For Baffle/Spade Castings

The removal of the sprue is an important process in casting manufacturing.This paper focuses on the removal of sprue and allowance for a series of large baffle and shovel plate castings of Ningxia Suning New Energy Equipment Co.For the removal of sprues and allowances of large baffle and shovel plate castings,there are difficulties in the number of sprues and allowances,complex distribution and large size of sprues.At present,the use of manual and semi-automatic equipment to complete the removal of the sprue,there are low efficiency,labour intensity,working environment and other problems.Checking the existing pouring and gating removal equipment at home and abroad,there is no equipment that can meet the efficiency and automation needs of enterprises.According to the enterprise’s demand for efficiency and improvement of the processing environment,a large automatic sprue removal machine is designed for the sprue removal of Baffle/Spade Castings.The basic requirements of the design are firstly determined,and the efficiency and Functional elements of the remover are decomposed through the functional analysis method,the functional elements are solved by constructing a morphological matrix according to the requirements of the company.The designed riser removal machine only completes the roughing process of the riser removal and does not involve subsequent grinding and finishing.The casting is analysed to determine the removal process,the requirements of the remover are analysed through the 5W2H method,the functional elements of the remover are decomposed through the functional analysis method,the functional elements are solved by constructing a morphological matrix,the optimal solution is determined by combining the hierarchical analysis method and the fuzzy comprehensive evaluation method,and the design of the whole machine is completed.The layout and positioning of the table,the linear movement of the table,the cutting feeder and the rest of the mechanism are then designed according to the scheme design and design parameters.The analysis of the castings’ risers was carried out to determine the best sequence of riser removal and different riser removal processes according to the distribution of the castings’ risers,combined with the process flow diagram of the remover to draw the movement cycle of the remover and complete the efficiency analysis.The control mode of the removal machine is determined as template control,the overall control scheme and control flow is described in conjunction with the riser cutting sequence,and the selection of PLC and other components is completed.Finally,the kinematic law of the removal machine was analysed,and the kinematic model was constructed and imported into Adams for kinematic simulation and verification of the whole machine,taking the largest size 2450mm baffle casting of the company as an example.The results show that the cutting device can achieve the movement of the set trajectory without interference,the movement is smoother and the removal efficiency meets the requirements,which verifies the rationality of the design of the removal machine.In this paper,the design of casting riser removal machine for stop and shovel castings was completed,and the feasibility and rationality of the design was verified by Adams software simulation,which provided technical support for intelligent removal of casting riser for enterprises.